Fluid Monitoring and Management Devices

ABSTRACT

A fluid monitoring and management device that includes a housing with a fluid passageway. The fluid monitoring and management device further includes a fluid property sensor with a sensing element in the fluid passageway. A valve is in the fluid passageway of the fluid monitoring and management device. A removable bottle mount is aligned with the valve to be selectively in fluid communication with the fluid passageway.

CROSS REFERENCE TO RELATED APPLICATION

This application does not claim priority from any other application.

TECHNICAL FIELD

The subject matter of this application relates to fluid monitoring andmanagement devices, systems and methods.

BACKGROUND OF THE DISCLOSURE

Fluids and liquids are the “life blood” of equipment and machineryhaving moving components. How goes the fluids/liquids, goes theequipment/machinery. That is, the health of the equipment/machinerydepends on the fluids/liquids. Exemplary fluids/liquids utilized inequipment/machinery include fuel (i.e. diesel, kerosene, gasoline,etc.); fluid lubricants such as grease and oil; coolants such as glycoland water; and process fluids such as hydraulic fluid.

Consider an internal combustion engine in an automobile. Engine fuel isthe liquid that powers the engine to drive the automobile. Enginecoolant is a fluid that flows through the engine to prevent overheating.Engine oil and transmission fluid are the lubricants that reduce wear onmoving parts; clean and inhibit corrosion; improve sealing actions; andfurther cool the engine and transmission, respectively. Hydraulic fluidis the medium for transferring power or action between respectivesystems, such as, from steering wheel to road wheels (power-assistedsteering system) and from brake pedal to brake pads, etc.

If the “health” of any one of these fluids is compromised or diminished,the “health” of the engine and/or automobile is compromised ordiminished which ultimately can lead to a catastrophic failure of theengine or automobile. Consequently, there always is a need for improvedfluid monitoring and management devices, systems and methods to predictand prevent diminishing health of the fluids, and correspondingly, theequipment and machines that the fluids protect.

While the subject matter of this application was motivated in addressingissues of fluids, it is in no way so limited. The disclosure is onlylimited by the accompanying claims as literally worded, withoutinterpretative or other limiting reference to the specification, and inaccordance with the doctrine of equivalents.

Other aspects and implementations are contemplated.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the various disclosures are described belowwith reference to the following accompanying drawings. The drawings maybe considered to represent scale.

FIG. 1 is an exploded view of an exemplary fluid monitoring andmanagement device of an exemplary fluid monitoring and management system(collectively fluid device/system) according to one of variousembodiments of the invention.

FIG. 2 is a partial sectional and partial cutaway of the fluiddevice/system of FIG. 1.

FIGS. 3A, 3B, 3C and 3D are different perspectives of partial sectionalsof the fluid device/system of FIG. 1 illustrating exemplary fluid flows.

FIGS. 4-13 are different perspectives of various components of the fluiddevice/system of FIG. 1.

FIGS. 14A and 14B are schematic views of an exemplary fluid monitoringand management system according to one of various embodiments of theinvention including the fluid monitoring and management device of FIG.1.

FIGS. 15A-15B are flow charts of various exemplary fluid monitoring andmanagement methods according to various embodiments of the invention andusing the fluid monitoring and management device/system of FIGS. 1-14.

FIGS. 16-22 are flow charts of various exemplary fluid monitoring andmanagement methods according to various embodiments of the invention andusing the fluid monitoring and management device/system of FIGS. 1-14.

FIG. 23 is a schematic view of the exemplary fluid monitoring andmanagement method of FIG. 22.

FIG. 24 is Dynamic Viscosity over Oil Temperature in C scatter plot forvirgin oil.

FIG. 25 is Baseline Viscosity curve fit.

DETAILED DESCRIPTION OF THE EMBODIMENTS

This disclosure is submitted in furtherance of the constitutionalpurposes of the U.S. Patent Laws “to promote the progress of science anduseful arts” (Article 1, Section 8).

The terms “a”, “an”, and “the” as used in the claims herein are used inconformance with long-standing claim drafting practice and not in alimiting way. Unless specifically set forth herein, the terms “a”, “an”,and “the” are not limited to one of such elements, but instead mean “atleast one.”

The inventive fluid monitoring and management devices, systems, andmethods disclosed in this application include a technology platform,data analytics, and fluid quality analysis services that, when combinedor used separately, provide real-time condition monitoring andintelligent health perspective of equipment (and/or machines, machinery)that utilizes liquids (fluids) discussed previously (again, such as fuel(i.e. diesel, kerosene, gasoline, etc.), fluid lubricants such as greaseand oil, coolants such as glycol and water, and process fluids such ashydraulic fluid, etc.). It should be understood that any reference inthis document to any variation of fluid monitoring and managementdevices, systems, and methods such as “fluid devices,” “fluid systems,”or “fluid methods” are all inclusive and applicable to the same concept.

Consider one specific use: intelligent health and real-time conditionmonitoring of lubricants (e.g. lubricating oil) for processingcompressor packages (compressor & engine) utilized in the globalon-shore/off-shore oil & gas industry.

Since the beginning of the modern industrial revolution, use oflubricants (e.g. lubricating oil) has provided the necessary function ofreducing friction and heat from the moving/sliding parts of mechanicalequipment. In reciprocating equipment with rotating shafts such asinternal combustion (IC) engines and compressors, synthetic, partiallysynthetic or hydrocarbon-based oil is used to reduce the friction(lowering the heat) and carry away tiny wear metal particles from themating interface of internal mechanical components such as piston rings& cylinder walls, valve stems and valve guide bearings, crankshaftjournals and corresponding bearings, meshed gear teeth, cam shaft lobesand cam followers, etc.

The enemy for this essential lubricating oil tasked with keeping themechanical parts generously lubricated is heat. As the oil heats up fromexcess friction and/or inadequate cooling of the mechanical equipment,the oil base-stock will begin to oxidize and breakdown causing the fluidto become acidic in nature, thus promoting corrosion of the metal partsthe lubricating oil is supposed to protect. Fuel dilution from “blow-by”in the combustion chamber of an IC engine is another culprit that candegrade the integrity of engine oil. As the piston rings wear fromconstant reciprocating movement and friction against the mating cylinderwalls, the raw fuel from the compression stroke, as well as combustiongases from the ignition & exhaust stroke (ref. Otto cycle), can slip bythe piston rings and enter the crankcase containing the engine oilreservoir. Hence, the lighter hydrocarbon (fuel) will dilute the thickerlubricating oil, compromising the ability to provide adequatelubrication of the mechanical parts.

Moreover, the dynamic viscosity of the oil (measure of how thin or thickthe fluid is, value of one centipoise (1 cP) being that of water) is anengineered property that provides the oil with specific flow,lubrication, and surface adhesion characteristics which are essential tobe maintained in order to facilitate proper lubrication of themoving/sliding parts, even under the harshest of operating conditions,for example, heat and shear. As the oil breaks down due to excess heat,it oxidizes, thus increasing the viscosity (making the oil thicker).

Degraded oil with a higher viscosity loses the ability to properly flowthroughout the small passages and tolerances between the moving/slidingsurfaces thus compromising the ability to remove the heat of friction.This condition leads to higher metal wear stemming fromsurface-to-surface abrasion, increasing the particulate contaminant loadof material constituents such as copper, iron, silicon, manganese,nickel, cobalt, molybdenum, etc. Proper equipment lubrication systemsare designed to carry away the wear metal particulate contaminants byrecirculating the oil flow under pressure via flow-through filtrationelements and size-exclusion based on the diameter of the targetedparticulate size.

Alternatively, as the oil is exposed to excessive shear forces,molecules will break down causing the viscosity to decrease. This “thin”oil is unable to properly cushion the moving/sliding metal surfaces andthe likelihood of metal-metal contact within the engine increases. Ifthere is metal-metal wear present in an engine, there will be a greatdeal of friction and heat generated at the point of contact, severelyreducing the life of the affected components. Wear-metal generation willalso increase which contributes substantially to the abrasivecontaminant loading in the lubricating oil.

Manufacturers of engineered lubricating oils fortify the oil by blendingit with “additives” to extend the operating life of the oil while alsoincreasing the range of harsh conditions the oil can be used under; thegoal is to develop an oil that can be used in more abusive conditionsand run longer between oil change intervals. Increasing the “alkalinityreserve” of the oil (as measured by the Total Base Number in units of mgKOH/gm) extends the length of time the oil can be used before theoxidation and nitration of the oil turns it into a more acidic fluid.The measurement of the oil acidity is determined by the amount ofpotassium hydroxide (in mg) that is needed to neutralize the acids inone gram of oil. Total Acid Number (TAN) in mg KOH/gm is an importantcharacteristic that determines the useful life of the oil. A lower TANindicates that the oil exhibits higher acidity and is nearing end ofuseful life.

A typical additive package (“add-pack”) contains detergents such ascalcium, magnesium, oxidation inhibitors such as sulfur, and naturalmetal lubricating agents such as zinc and phosphorus. The lubricatingoil used in an IC engine finds its way into the combustion chamber andis “consumed,” or burned along with the fuel and then expelled via theexhaust system. When burned in the combustion chamber, the add-packconstituents blended in with the oil base-stock produce an ash depositon the interior surfaces of the combustion chamber and exhaust valvesurfaces. These ash deposits are combustion by-products that are theresult of burning fuel and engine oil during the engine's normaloperation. Such deposits are in the form of small (>4 micron), hardparticulates that have the capacity to contaminate the recirculatingengine oil. The engine oil, contaminated with tiny, abrasive particleswill severely damage the engine components if unfiltered and leftunchecked. This excessive wear condition can lead to a dramaticallyreduced equipment life and operating efficiency.

An exemplary embodiment of the inventive fluid monitoring and managementdevices, systems and methods can be deployed, as one non-limitingexample, in the Oil & Gas industry, specifically in the Midstream marketfocused on providing intelligent equipment health condition monitoringof rotating equipment such as, but not limited to, reciprocatingcompressors and internal combustion engines.

Non-limiting applications for the inventive fluid monitoring andmanagement devices, systems and methods include: a) natural gasgathering and compression application, compressor package comprised of anatural gas-fired internal combustion engine powering a reciprocatingmulti-stage compressor; b) monitoring the oil quality and consumption ofthe primary oil lubricating system for the driver (IC engine), i.e.engine crankcase, valve train, and piston lubrication, turbolubrication; c) Monitoring the oil quality and consumption rate of thecrankcase lubricating oil system for the compressor; d) Monitoring theoil quality and consumption rate of the high-pressure cylinderlubricating oil system for the compressor; e) in situ monitoring of oilquality and consumption; and f) scheduled (routine) and exception-basedoil sample collection wherein oil samples are collected via an automatedsolenoid actuated valve driven by a microprocessor controlled autonomousalgorithm thereby eliminating the human interface (exception-based rulesare unique and based on custom algorithm that determines a ‘dangerouscondition’ event or threshold has been detected).

Inventive fluid monitoring and management methods include, asnon-limiting examples only, using the fluid devices and systems tocollect fluid samples via an automated solenoid actuated valve driven bya microprocessor controlled autonomous algorithm, thereby eliminatingthe human interface. Exception-based rules in the algorithm determinethat a “dangerous condition” detected or that a threshold value has beenreached or surpassed. Moreover, fluid (oil) sample analysis can beprovided by a third party lab utilizing industry recognized ASTMprotocols.

Referring to FIGS. 1-13, an exemplary, non-limiting embodiment of aninventive fluid monitoring and management device 10 (hereinafter mostoften stated as “fluid device” for simplicity and can be considered oneof various exemplary embodiments of a fluid system 120) is described. Itshould be understood that FIG. 1 is representative of one, non-limitingexample, of an exploded view of the fluid device 10 with additionalFIGS. 2-13 more readily illustrating various aspects of specificcomponents of fluid device 10. It should be further understood thatfluid device 10 described throughout this document is applicable tomonitor and manage the utilization of any fluid in any equipment,apparatus and/or machine. However, the focus of the followingdescription of the fluid device 10 (and fluid monitoring and managementsystems and methods) is directed to, as only one of various possibleembodiments, as being utilized with a fluid such as a lubricant, andmore specifically, to oil circulating through an engine.

Fluid Device

Referring to FIG. 1, an overview of the major components of the fluiddevice 10 is first summarily presented to facilitate a more thoroughsubsequent discussion of the components. A bezel 63 is secured in arecess in a lid 40. Lid 40 houses a printed circuit board assembly 111(PCBA) and a weatherproof seal 110 is provided over the PCBA 111 in thelid 40. Lid 40 is secured over an opening 16 in an upper housing 12.Upper housing 12 receives in opening 16 a solenoid valve cartridgeassembly 19 (solenoid or solenoid cartridge) and a sensor package 70.Sensor package 70 includes a fluid property sensor and a fluid pressuresensor. A lower housing 50 is secured to upper housing 12 with variousseals 25/27 in between. A sample collection housing 18 is secured to thelower housing 50. The sample collection housing 18 encloses (houses)sampling bottle 34 (sample bottle), sample bottle mount 80 (bottlemount) and user interface plate assembly 60 (user interface panel).Secured to user interface panel 60 is a removable flash data storage key90, a reset button 91 and a data/configuration port 93. A door 24 ispivotably secured to sample collection housing 18 wherein the door 24has a latch 30 and a sample bottle cap 32. Bezel 63 and lower housing 50each have a light-emitting diode (LED) 49 and 69 respectively. Bottlemount 80 has two o-rings 41/53 and various fasteners 42/94/96/97 securevarious components of the fluid device 10 together.

The exemplary fluid device 10 has a body construction (main housing)that includes an upper housing 12 removably secured to a lower housing50. An exemplary body (upper and lower housings) 12/50 is the mainstructure of the fluid device 10 and ultimately supports additionalstructures and is used to attach and mount the fluid device 10 tosubject equipment being investigated for oil usage (for example, engineand/or compressor). The body 12/50 is the mount and protection forsensors from damage, as well as sealing structures for the constant flowof fluid (oil) from the engine and/or compressor through the fluiddevice 10. The body 12/50 also provides for weathertight/explosion-proofconduit connections for power supply and data signal wires.

Still further, processed data from a microprocessor exits the body 12/50via wires and is transmitted back to a Data Aggregator/CommunicationsHub (optional wireless connectivity). The body 12/50 is a computernumerical control (CNC) machined aluminum multi-part housing that formsthe structural element designed to be sufficiently strong to withstandthe rigors of abusive environment typical of oil & gas industry.

Moreover, the fluid device 10 is designed to operate equally wellindoors as well as outdoors and includes generally a six (6) mainpieces/components in the design which are more thoroughly describedsubsequently: main Upper Housing 12, Lower Housing 50, User InterfacePlate Assembly 60 (or User Interface Panel), Sample (sampling) BottleMount 80 and Lid 40.

An exemplary upper housing 12 (sensor housing) of fluid device 10 formsthe main housing component body 12/50 and secures/attaches the fluiddevice 10 to subject equipment with an equipment-specific, load bearing,vibration-isolating bracket. An exemplary bracket is attached viafasteners (threaded bolts) that thread into drilled and tapped holes inthe metal upper housing 12. Proper torque setting of the bracket screwfasteners in an interface of upper housing 12 overcomes the likelihoodof loosening of the fasteners as the fluid device 10 is subjected toconstant vibration during normal operation.

Upper housing 12 has an opening 16 through a top portion of thestructure that terminates at a lower surface 17 (FIG. 2). In situ sensorbodies, for example, fluid property sensor 70 (and pressure sensor) andsolenoid assembly 19, are threaded into the lower surface 17 of upperhousing 12. In one embodiment, upper housing 12 is made from CNCmachined solid billet aluminum. Alternatively, upper housing 12 is madefrom near-net shape investment cast aluminum with secondary CNCmachining operations to provide tight tolerance features. Upper housing12 has a detailed seal gland design that provides for the provision ofweatherproof high-reliability sealing at interface between lid 40 andupper housing 12. Tapped holes (openings) 87 (only one shown in FIG. 1)(NPT or Machine Thread with o-ring boss seal) on opposing sides (leftand right) of the upper housing 12 facilitate installation of inlet andoutlet oil line (SS Swagelok™ fittings) in support of leak-freerecirculating oil flow to and from the engine. In one embodiment, upperhousing 12 is installed such that an oil path is horizontal and level tofacilitate a fluid (oil) sampling. Another opening (hole) 14 in side ofupper housing will have/receive electrical conduits for electrical/datacommunication with electronics of fluid device/system 10/120, forexample, a printed circuit board assembly (PCBA) 111.

In one non-limiting example, engine oil is supplied from a high-pressureengine oil pump that is plumbed from an engine block (for example,gallery ports) to upper housing 12 via SS tubing. An oil return line isfrom the upper housing 12 to the engine oil sump (at near-atmosphericpressure, 0-1 psig) and plumbed from fluid device 10 to engine crankcasevia SS tubing. Since there is a high pressure differential across thelength of the upper housing 12 (between the oil supply ˜60 psig, and oilreturn ˜atmospheric, 0 psig), a provision has been made for a removable,machined threaded orifice plate in the oil exit side of the upperhousing 12. This orifice feature will allow for maximizing the pressuredrop across the fluid device 10 by reducing the oil flowrate through theupper housing 12. Hence, the measured oil pressure within the oil linecan be managed so that the measured pressure is closer to the operatingpressure of the engine.

Alternatively, an engineered orifice opening can be machined into theoil exit port as an integral feature of the upper housing 12. In oneembodiment, a variable orifice would be incorporated to provide thecapability of varying orifice diameters for the purposes of fine tuningthe oil flow rate vs. oil pressure differential balance. In oneembodiment, the fluid device 10 is mounted to maximize the oil supplyflowrate available to the upper housing 12 and fluid device 10.

An exemplary dimensional length of the upper housing 12 is such that thein situ (in-line) sensors can be arrayed in a manner that theyconveniently fall within the path of the integral oil line. Should therebe a need for additional in situ sensors, and/or solenoid actuated valvebodies, the length of the upper housing 12 can be increasedappropriately. The dimensions of mating lower housing 50 and lid 40would correspondingly increase in dimensions to match.

Fluid device 10 further includes a lid 40 that is a housing componentremovably secured/affixed to the top of upper housing 12 viatamper-resistant fasteners or screws 42 (in support of “intrinsicallysafe” design practices). When assembled, the upper housing/lowerhousing/lid 12/50/40 sub-assembly form a weather-tight, IP67 rated,intrinsically safe enclosure housing the sensitive electronics andsensors for fluid device 10.

All aluminum outer surfaces of the fluid device 10 are finished with abaked “Safety Orange” ceramic coating (Cerakote®) to provide extremelytough, abrasion resistant surface to protect the lid 40 from rigors ofthe Oil & Gas environment. For offshore applications that are exposed toopen water, salt water spray, and the worst of inclement weather, theceramic coating provides the lid 40 with an excellent and superiorfinish.

As stated previously, an exemplary fluid device 10 includes the lowerhousing 50 removably secured to the upper housing 12. The lower housing50 forms substantially a portion of the oil flow path that enters andexits the upper housing 12 from the engine. The lower housing 50establishes the oil flow path bottom and sides which is engineeredspecifically to provide consistent and high quality oil samples andsensor readings. Furthermore, lower housing 50 allows for the connectionof the oil sample bottle mount and the protective sampling enclosure.The lower housing 50 additionally contains the mounting location for theremovable User Interface Panel (plate) 60.

The oil flow path for the fluid device 10 is designed so that the insitu fluid property sensor 70 (FPS) is constantly able to producemeasurements that are representative of the oil flowing through thefluid device 10 at any given time. These measurements are highlyrepeatable and are accurate. In order to maintain high quality sensordata over the life of the fluid device 10, the oil flow path is designedwith features that promote scouring of the sensor elements (sensingelements) through the creation of intensely turbulent zones of oil flowaround the in situ sensor elements (described and shown more thoroughlysubsequently). This self-scouring feature eliminates the need forregular cleaning or replacement of the fluid property sensor 70 andensures that quality data will always be produced.

It should be understood that in one embodiment, a representative fluidproperty sensor can be purchased from Measurement Specialties™ having aninternet address of www.meas-spec.com. A specific representative fluidproperty sensor is listed as FPS2800B12C4-Fluid Property Sensor Module.

Referring to FIG. 1 and more specifically to FIG. 2, the fluid device 10includes a solenoid assembly 19 to allow oil to exit the flow path andfill a sampling bottle (sample bottle) 34 as needed or indicated byfluid device 10. The solenoid assembly 19 comprises a electromagneticcoil 43 surrounding a solenoid actuated needle 37, and a needle valve 39(solenoid needle valve or valve needle) including a sampling orifice 35.The solenoid assembly 19 is designed for ultra-high pressureapplications. The sampling orifice 35 is positioned above a samplingvalve body 33. At lower pressures, for example less than 150 psi (<150psi), the solenoid assembly 19 exhibits a leak rate that is effectivelyzero. This means that the solenoid assembly 19 will not drip into thesampling bottle 34, and therefore, is either on or off. In oneembodiment, the operational pressure range for the solenoid 19 actuatedvalve is from about 5 psi to about 150 psi.

Still referring to FIG. 1 and FIG. 2, the fluid device 10 includes asample bottle mount 80 (also bottle mount) that is interchangeable toaccommodate different sample bottle collection geometries. In oneembodiment, an oil sample collection is a 4.2-oz. (125 mL) clear plastic(PET) wide-mouth bottle that has a thread and a twist-on sealing screwcap with a thread size defined as 38-400. For an exemplary oil sampleanalyses which includes a standard set of ASTM protocol tests, thesample volume required is 4.2-oz. However, if a more extensive set ofoil analyses to be performed is desired, a larger volume of oil may berequired wherein a larger 8-oz. sized PET bottle can be used. In theinstance where the larger bottle may have a larger bottle mouth, orpossibly have a screw thread that is different than the 4.2-oz. bottle,the fluid device 10 accommodates different bottle mouth/threadgeometries.

The interchangeable sample bottle mount 80 (bottle mount) threads ontothe underside of the lower housing 50, and while in the fluid device 10,is in a co-axial orientation/configuration with the needle valve 39. Thebottle mount 80 is a precision-machined metal part that when threadedonto the lower housing 50, mates up to a machined flat surface thatforms a seal and land area for a shoulder of the needle valve 39. Thebottle mount 80 has valve body mating surface 51 and a small ventorifice 85 (tiny pinhole vent (vent hole) that allows oil/air to escapefrom inside the sample bottle 34 during an oil sample collection event.Moreover, the bottle mount 80 has geometry features (i.e. flats, hex,spanner slots, etc.) that allow for a tool to be used to install thebottle mount 80 to the lower housing 50 and apply the appropriate amountof torque to insure the bottle mount 80 will not loosen during exposureto constant vibration.

The sample bottle mount 80 is aluminum and is designed to form the lowerbody of the sampling valve and the oil flow path sealing surface. Thebottle mount 80 includes the tiny pinhole vent (vent hole) 85 to allowoil/air to escape during an oil fill event. The vent 85 is recessed nearthe threads of the bottle mount 80 to prevent contamination such as fromdust. Contamination prevention maintains a sterile oil sample bottle 34to ensure that contamination does not bias or influence ultimate oilanalysis results. The bottle mount 80 is designed with a steppedshoulder to receive a felt pad 61 so that the felt pad 61 can beinstalled between the lower housing 50 and the bottle mount 80. The feltpad 61 acts as an air filtration mechanism for the vent hole 85. In oneembodiment, the bottle mount 80 has a large hex head to facilitategripping with a wrench for easy removal. In one embodiment, the bottlemount 80 has a thread pattern 1-32 UN for installation in the lowerhousing 50 that ensures a reliable, high quality seal.

Mating threads on the bottle mount 80 for securing the sample bottle 34are designed/configured to be slightly undersized to squeeze the samplebottle threads and create a strong friction fit. Furthermore, thisthread configuration is designed to prevent loosening of the samplebottle 34 due to the effects of vibration and high temperatures overtime.

Since the bottle mount 80 establishes the lower valve housing and aportion of the oil flow path, the bottle mount 80 is sealed withredundant o-rings 41 and 53. A first o-ring 41 is located at the base ofthe threads (from FIG. 2 view) of the bottle mount 80 near or adjacentthe bottom surface of the lower housing 50. A second o-ring 53 islocated near the top or terminal end of the threads (from FIG. 2 view)of the bottle mount 80. The second o-ring 53 is sized to protect thefemale 1-32 UN threads in the lower housing 50 from being damaged duringinstallation, replacement, or removal of the bottle mount 80.Additionally, this reduces the risk of damage to the threads of thebottle mount 80 during installation, particularly during low light orblind installation situations which can be common in the field. Thebottle mount 80 can accommodate sample bottle 34 size and bottle neckthread configuration, male or female. The bottle mount 80 is fieldchangeable so that sampling bottle 80 type can be modified at any timein the field.

In one embodiment of the fluid device 10, the bottle mount 80 includes aswitch actuation mechanism that allows the fluid device 10 to detect thepresence of a sampling bottle 34. One embodiment of a switch actuationmechanism includes a push rod that is interfaced to a pushbutton switchin the fluid device 10. The presence of a sampling bottle 34 results ina lifting action on the pushrod to activate the pushbutton switch.Another embodiment of a switch actuation mechanism uses a magnetic diskthat is lifted with the installation of a sampling bottle 34 which inturn activates a reed switch located inside the upper housing 12 of thefluid device 10.

The fluid device 10 can use a pressure transducer instead of the venthole 85 of the bottle mount 80 to determine if the sampling bottle 80 isfull of oil. In this design, the sampling bottle 80 is airtight during asampling event and as the oil fills the volume of the sampling bottle80, the oil will displace the air in the sampling bottle 80 causing arise in air pressure until a threshold pressure is reached indicating anoil sample is collected.

Referring to FIGS. 3A and 3B (and FIGS. 3C and 3D subsequentlydescribed), a sectional of the lower housing 50 of the fluid device 10is illustrated and exposes a portion of a fluid property sensor 70 in aportion of a fluid passageway 71 (pathway, passage, path, or circuit,flow path). The fluid passageway 71 of fluid device 10 is designed sothat the in situ fluid property sensor 70 and the solenoid assembly 19,respectively, are consistently able to produce accurate measurements andoil samples that are representative of the oil flowing through the fluiddevice 10 at any given time. The data produced from oil samples by thefluid device 10 and from any lab analysis are required to be of thehighest quality and repeatability. The fluid device 10 uses high speedflows as well as a strategically located square change (sharp squaresteps 104 and 105 (see FIG. 9)) in floor depth of the fluid passageway71 to create a phenomenon known as a “Hydraulic Jump” in the flow of thefluid. This condition ensures that turbulence and mixing of oil ismaximized in the fluid flow through the fluid passageway 71 proximate tothe fluid property sensor 70 and solenoid 19.

Still referring to FIGS. 3A and 3B, oil flow (fluid flow) 73 moves fromleft to right in this view. A sensor element (sensing element) 100 ofthe fluid property sensor 70 is mounted in a protective cage 101.Protective cage 101 has elongated openings 102 that arecircumferentially spaced around the protective cage 101 and extendvertically. The elongated openings 102 expose the sensor element 100 tothe environment outside the protective cage 101 and fluid propertysensor 70. In uniform fluid flow conditions, the protective cage 101creates eddy currents and stagnate zones that promote deposit build upand sensor fouling. However, the fluid device 10 has the fluidpassageway 71 configured to prevent accumulation of deposits.

In order to maintain high quality sensor data, the fluid passageway 71has features that promote scouring of the sensor element 100 of thefluid property sensor 70 through the creation of intensely turbulentzones of oil flow around the in situ sensor element 100. Thisself-scouring feature eliminates the need for regular cleaning orreplacement of the fluid property sensor and ensures that quality datawill continually be produced.

In one exemplary fluid device 10, the fluid passageway 71 includes floor106 that extends to at least one sharp square step (sharp step) 104which extends to another floor 107 structure at a lower elevation thanfloor 106. Another (or second) sharp square step (sharp step) 105 (seeFIG. 9) impacts fluid flow characters for solenoid 19 the same as theflow fluid characteristics described subsequently for fluid propertysensor 70 due to square step 104. In one embodiment, the floors 106 and107 are planar and generally parallel with the sharp step 104 (and forsharp step 105) extending at ninety degrees relative to each floor 106and 107. Fluid passageway 71 includes a wall 108 opposite the sharp step104 that extends at ninety degrees from floor 107 and relative to thefloor 106.

The oil flows through the fluid passageway 71 over floor 106 until itencounters the sharp step 104. As the oil flow encounters the sharp step104 and the different floor depths, the velocity of the oil flowdecreases (and for sharp step 105). Moreover, the sharp step 104 causesthe oil flow to tumble 73/75 as it is sheared by the slower moving oilflow at the base of sharp step 104 (and for sharp step 105). The oilflow then encounters wall 108 to be diverted toward the sensor element100 in a ninety degree change of oil flow 73/77 direction from theoriginal oil flow 73 over floor 106.

If the oil flow was uniform at this stage of encountering the wall 108,the oil flow would simply change direction in a uniform manner and enterthe fluid property sensor. This oil flow would have minimal mixing andpromote formation of eddy currents, which as stated previously, promotesdeposit build up and sensor fouling detrimental to consistent andaccurate data collection.

However, in the fluid passageway 71 configuration just described forfluid device 10, the oil flow tumbles and encounters the sensor element100 in a spinning, cork-screw flow pattern. The combination of the sharpstep 104 and the wall 108 (ninety degree turn) in the flow path createsa spinning flow that eliminates the potential for deposits collecting onthe delicate sensor element 100 (and same fluid flow characteristics forsharp step 105 and solenoid 19).

Still further, the configuration of the fluid passageway 71 for fluiddevice 10 creates a high velocity and highly turbulent flow around thesampling valve body 33 of solenoid 19 (FIGS. 2 and 9) due to sharpsquare step 105 (FIG. 9) (and having same fluid flow characteristics assharp step 104) which ensures that no deposits form near the valveorifice 35. Without this feature, the presence of deposits may lead tooil sample contamination or improper sealing of the valve needle 37against its seat. It should be noted that the oil sampling valve isthreaded into the housing 12/50 of the fluid device 10 and that the oilflow should be able to scour the valve sealing surfaces for any finalorientation of the valve as it is screwed in the housing. This isaccomplished by creating flows on either side of the sampling valve body33 that possess very different pressure and velocity characteristics.The result of this is a very high oil flow velocity perpendicular to theflow path at the location of the sampling valve body 33.

In creating zones of intense turbulence for the purposes of scouring, agreat deal of energy is dissipated in the oil as it flows through thefluid device 10. This serves to create a pressure drop across the fluiddevice 10 which allows for the measurement of oil pressures that closelymatches the engine oil pressure.

Referring to FIGS. 3C and 3D, the fluid flow through fluid device/system10/120 is described from a different perspective. The construction ofthe sensor element 100 of the fluid property sensor 70 incorporates aprotective cage 101 configuration that encompasses the senor element100. In uniform flow conditions oil flowing through the openings 102 inthe cage 101 creates eddy currents and stagnant zones (low pressure, lowflow zones) that promote buildup of oil precipitates (varnish) thatwould foul the sensor element 100 rendering the measured data inaccurateor the fluid property sensor 70 inoperable.

Prior attempts to use in situ oil property monitoring have been plaguedwith damaging varnish build ups on the sensor elements that have led toreduced sensor life and measurement accuracy. In order to prevent suchproblems, the fluid device/system 10/120 described throughout thisdocument incorporates a novel and unique flow path design.

As the oil flows in a laminar fashion (low Reynolds number) through thefluid device/system 10/120 (recirculating through the engine 15; FIG.14A), it first encounters a sharp step 104 (and step 105 shown in FIG.9) in the floor of the oil path asymmetrically increasing thecross-sectional area of the oil path, thus unevenly decreasing thevelocity of the oil (consider the Bernoulli principle). This sudden anduneven velocity change causes the oil to “tumble,” both roll upwardsaway from the step and to curl downwards to fill the extra area createdby the step 104 (and step 105). The rolling and curling behavior of theoil flow 71 is a result of the flow shearing between the faster movingoil near the top of the flow path 71 and the slower moving oil in thebase of the flow path 71 and within the step 104 and step 105). Thisrolling and curling behavior makes use of the phenomena known as a‘hydraulic jump’ which causes the fluid to behave in a way thatresembles a rip-tide as waves break on a beach, again, at least in part,due to sharp steps 104 and 105. As the oil tumbles and curls, it becomesintensely turbulent, raising the Reynolds Number of the flow. As theReynolds number is nothing more than an expression for the ratio betweenthe inertial forces of a fluid and the viscous forces, the increasedReynolds number allows the inertial forces to dominate the flowcharacteristics, thereby minimizing the potential size of any stagnationzones or eddy currents within critical parts of the oil flow path 71.

The “tumbling,” rolling and curling oil then encounters a sharp, 90degree turn 108 relative to the flow path 71 of the oil. Under normalconditions (with uniform flow), the oil would simply change direction ina uniform fashion and enter the sensor with very little mixing whichwould promote the formation of eddy currents, especially on the insideof the flow path after the 90 degree turn and on the inside face of theprotective cage 101 of the fluid property sensor. However, in the caseof the inventive fluid device flow path 71, the flow 71 begins to tumbleand spin before it enters the fluid property sensor 70 in a spinning,cork-screw flow pattern. The combination of the square step 104 in theflow path 71 and the 90 degree turn 108 of the oil creates a spinningflow that eliminates the potential for deposits collecting on thedelicate sensor elements 100.

In one embodiment, the 90 degree turn 108 can range from about 60degrees to about 120 degrees relative to the flow path 71 of the oil.Moreover, while the sharp square step 104 is effectively a surfaceoriented at 90 degrees extending between the two planar and parallelsurfaces, the square step 104 can be oriented to range from about 60degrees to about 120 degrees extending between the two planar andparallel surfaces.

Referring to FIG. 9, sharp square step 105 is shown adjacent, andupstream from, a port 109 (opening) for solenoid 19. The configurationand dimensions of sharp step 105 can be the same as the configurationand dimensions of sharp step 104. In one embodiment, sharp step 104 hasdifferent dimensions relative to the dimensions of sharp step 105. Inone embodiment, sharp step 104 has a different configuration relative tothe configuration of sharp step 105. In one embodiment, sharp step 104has different dimensions and a different configuration relative to thedimensions and configuration of sharp step 105. Opening or port 109 inlower housing 50 receives solenoid 19 body. It should be noted that port109 has a specifically designed geometric shape that facilitates andpromotes orifice scouring wherein the orifice is for sampling of thefluid flowing in the passageway 71 via solenoid 19 described throughoutthis document. Recess areas 115 in lower housing 50 reduce thermalconduction from the fluid circulating through passageway 71 such as oilat a high temperature.

Referring to FIG. 13, lower housing 50 is again illustrated and showsinlet/outlet ports 118 for a fluid entering and exiting lower housing 50and passageway 71. Still further, port 117 receives a pressuretransducer and port 119 receives fluid property sensor 70.

As the goal of the flow path 71 of the fluid device/system 10/120 is topromote a controlled, spinning flow that is devoid of stagnation zones(areas of the sensor element 100 surfaces which have zero fluid velocitypast them), uniformly scouring the sensor element 100 surfaces toprevent build-ups from happening. Due to the need to eliminatestagnation zones around the sensor element 100, the flow path 71 cannotsimply be made rougher or less direct. The result of features such asincreased surface roughness or “speed bumps” along the flow path 71would result in uncontrolled and somewhat random zones of fluidstagnation in close proximity to the sensor.

Still referring to FIGS. 1-13, the fluid device 10 includes, betweenupper and lower housings 12/50, high pressure oil seals (gaskets) 25/27configured as form-in-place (FIP) seals (gaskets) that are designed toresist the oil pressure imparted by the engine oil pressure system. Inone embodiment, exemplary oil pressure range from about 60 psi to about150 psi. An exemplary FIP seal design is a compression bead containedwithin a land area that when compressed to about 40% of vertical travel,the bead fills the land groove. A compression stop is integrated intothe design to prevent the sealing bead from being over compressed, thuspotentially causing a seal failure. In one embodiment, the seal designactually utilizes a double FIP seal path to provide a redundant oil sealproviding a safety margin. Dual seal design creates a backup seal toeliminate the risk of oil leaking out of the fluid device 10 flow path.Referring to FIG. 5, a primary FIP seal 81 and a secondary FIP seal 83are shown between upper and lower housings 12/50.

It should be understood that the reference to “40%” of vertical travelis based solely on the mechanical properties (hardness as measured bythe Shore Durometer Type A scale) of the specific silicone sealantmaterial used in this FIP application. If we chose a different sealantwith a softer (lower Durometer Share A value) or harder (higherDurometer Shore A value), then the compression value (e.g., 40%) wouldbe adjusted accordingly.

Exemplary seal material is silicone-based for use in high temperatureenvironments. Seals 25/27 provide a sealed environment for the sensitiveelectronic sensors in fluid device 10 that are placed in situ to theflow-thru oil path. Seals 25/27 (FIP gaskets) are applied to lowerhousing 50 to ensure a high quality, reusable seal and are removable,and therefore, can be re-applied in the event of seal damage.

Fluid device 10 includes a user interface panel 60. An exemplary userinterface panel 60 includes at least three devices for access tointeractive features of the fluid device 10. Exemplary devices mountedon user interface panel 60 are: 1) an on-board removable flash datastorage key 90; 2) a reset button 91; and 3) a data/configuration port93. The user interface panel 60 is pre-assembled prior to installationinto the lower housing 50 and incorporates an additional form-in-place(FIP) gasket 95 to provide an IP67 seal when properly assembled. Theuser interface panel assembly 60 can be removed in the field for fastcomponent change-out and ease of upgrade.

An exemplary reset button 91 is a lighted IP67 rated momentary pushbutton switch which allows for the operator of the fluid device 10 toeasily reset an oil sampling counter or to collect a manual oil samplevs. a scheduled oil sample. In one embodiment, the reset button 91 is alighted reset button that provides a visual status indication if asampling reset is required.

An exemplary removable flash data storage key 90 is a flash memorydevice that locally stores processed data acquired from or by the fluiddevice 10 and provided for archival retrieval when needed. If the fluiddevice 10 is installed without a wired/wireless data link to a database,then the archived processed data can be retrieved manually from the datastorage key 90.

An exemplary data/configuration port 93 allows users to locally connectthe fluid device 10 to a laptop for the purposes of viewing live data,configuring fluid device 10 settings, or performing a firmware update.In one embodiment, the data/configuration port 93 is a mil-spec IP67design with a ratcheted locking plug retention mechanism for vibrationresistance. In one embodiment, the sampling bottle mount is installedwith a 1^(5/8)″ wrench and features a precision machined landing surfaceso that it can be installed extremely tightly into the lower housing 50(lower body) without over-compressing the o-ring seals.

The fluid device 10 included the previously discussed lid 40 andprovides a cover to the upper housing 12 effectively sealing the fluiddevice 10 from weather, dust, water, gases, etc. The lid 40 alsoprovides mounting for the electronics package and product brandlabeling. Lid 40 incorporates a weatherproof seal 110, an integralform-in-place (FI P) seal made from oil resistant silicone. Acrush-proof land area is machined into the seal region to prevent theFIP seal bead from being over-compressed, thus potentially compromisingthe integrity of the seal. This design feature also minimizes themetal-to-metal contact area between the lid 40 and Upper Housing 12.Minimizing the metal-to-metal surface contact means there is lessopportunity for heat conduction from the Upper Housing 12 (heated by thehot engine oil coursing through the machined oil path) and the Lid 40which contains a printed circuit board assembly 111 (PCBA) with heatsensitive electronic components. The Lid 40 remains relatively coolcompared to the rest of the fluid device housing and allows for heat tobe conducted away from the electronics and into the Lid 40 via thecircuit board mounting hardware.

Machined into the Upper Housing 12 is a small “lip” that serves as ashear protection feature, preventing the mounting hardware and integralFIP seal from failing should the Lid experience a sideways blow. Shouldsuch an event happen, the shear lip will receive all of the shearloading and the small diameter mounting screws will be left to handletension only. An exemplary lid 40 is fastened to the Upper Housing 12with difficult to access tamper-resistant fasteners 113 to preventunwanted penetration into the sensitive area of sensors and electronics.The Lid 40 design, materials and fastening method supports guideline for“intrinsically safe” rating. An underside of Lid 40 is used to fastenthe PCBA 111. The Lid 40 is made from CNC machined aluminum (but couldbe cast aluminum) so as to provide an efficient heat conduction path fornaturally cooling the PCBA 111 heated by the board-mounted components.The external surface of the Lid 40 might also contain heat-rejectingfeatures, i.e. fins, to further reject heat, via passive convective heattransfer to the surrounding air.

Attachment points for the PCBA 111 utilize integrally machined aluminummounting headers (attachment bosses) which conduct heat away from thePCBA 111 through the pads and out the external surface of the Lid 40.The mounting bosses are arranged in a non-standard, non-symmetricalfashion with respect to the geometry of the PCBA 111. This processminimizes the potential harmonic vibrations that could resonate in thePCBA 111 while operating on a constantly vibrating machine. Any harmonicresonances present in the PCBA 111 could be very damaging to theintegrity of the PCBA 111, i.e. solder joints of the surface-mountedcomponents could fatigue, thus allowing the components to “pop off” theboard 111. A relatively large contact area between the PCBA 111 and themounting bosses will facilitate a greater conductive heat flux, thuscooling the PCBA 111 faster and more efficiently. The mating surfacebetween the mounting bosses and the PCBA 111 will be gold (PCBA 111) andmachined aluminum (Lid 40). In another embodiment, a heat conductingmaterial (washer, film, grease) can be laminated between the PCBA111/boss interfaces to increase the heat conduction efficiency, furtherprotecting the PCBA 111 from overheating.

Once the Lid 40 and PCBA 111 have been assembled, it is possible tocompletely encapsulate the PCBA 111 by flooding the Lid 40 with a heatconducting encapsulation formulation. The 100% encapsulation of the PCBA111 and related components will substantially add to tamper resistance,vibration stability, providing structural support to the electroniccomponents, i.e. discrete parts, surface mounted parts, etc. In oneembodiment, fluid device 10 includes all aluminum outer surfaces beingfinished with a baked “Safety Orange” ceramic coating (Cerakote®) toprovide an extremely tough, abrasion resistant surface for protectionfrom the rigors of an environment experienced in the Oil and Gasindustry. Furthermore, for offshore applications that are exposed toopen water, salt water spray, and the worst of inclement weather, theceramic coating will provide the fluid device 10 with an excellent andsuperior finish.

The fluid device 10 includes LEDs, for example LEDs 49 and 69 and lightpipes 79 (see FIG. 6). Light Pipe interface holes are machined to adimension for a snug press-fit of injection molded plastic (clear, lighttransmitting polycarbonate) Light Pipe components. Machined throughholes are counter-bored into the underside of the Lid 40 to position theface of Light Pipe very close (approximately 0.005 inch) to theunderside of clear Bezel 63 surface. A recessed pocket is machined intothe top (outer) surface of the Lid 40 to accept the adhesively bondedBezel 63. The depth of the recessed pocket is such that when installed,the top, upper most surface of the Bezel 63 is sub-flush by 0.005 in inorder to prevent the Bezel 63 from easily being peeled out off of theLid 40. This is a tamper-resistance and product durability feature.

Moreover, a through-hole antenna window is machined all the way throughthe top surface of the aluminum Lid 40 to allow radio waves to betransmitted from, as one example, a Bluetooth® 2.4 GHz PCB-mounted“patch” antenna, through the radio-transparent window and subsequentBezel 63. The Antenna Window is precisely located to align with thepatch antenna mounting location on the PCBA 111. A recessed pocket ismachined into the top (outer) surface of the Lid 40 to accept anadhesively bonded metallic Serial Number Plate (SNP). The depth of therecessed pocket is such that when the SNP is installed, the top, uppermost surface of the SNP is sub-flush by 0.005 in.

The Bezel 63 serves as a product label and user interface. Bezel 63construction is that of a laminated polymer featuring: a) pressuresensitive adhesive (PSA) layer (Adhesive Layer) that is on the bottom ofthe lamination stack and serves to permanently adhere the Bezel 63assembly to the aluminum Lid 40; a decorative graphics layer (GraphicsLayer) that contains the product branding, company information, productsafety information and user interface text and/or icons; a media layer(Media Layer); and a clear UV stabilized weather protection layer(Protective Layer). The Adhesive Layer features an application-optimizedpressure sensitive adhesive (PSA) for high durability bonding of theplastic Bezel 63 to the ceramic coated (ref. Cerakote®) finish of theLid-Bezel mounting surface (recessed pocket). The Graphics Layerfeatures the reverse printed product labeling which is selectivelyapplied to allow for visibly transparent windows that align with thelocation of each LED 49 indicator light, LCD display, lid 40 serialnumber, etc.

The Media Layer of bezel 63 features a plastic (polyester) sheet thatforms the majority of the Bezel's thickness. This material is UVinhibited and designed to hold up to prolonged high temperature exposureand outdoor operation with direct sun UV exposure. The protective layerfeatures a high hardness, UV blocking, satin textured coating to eachlabel that prevents ink pigment fade or label discoloration as a resultof long term outdoor operation of the product. This top coating reducesthe likelihood of scratches or degradation of the label in all practicalfluid device 10 installations. The bezel 63 is adhesively installed intothe recessed pocket on the top most outer surface of the Lid 40.

The solenoid cartridge 19 of the fluid device 10 utilizes a solenoidactuated needle valve to allow oil to exit the flow path and fill thesampling bottle 34. This needle valve is designed for ultra-highpressure applications and at lower pressures (<150 psi) it exhibits aleak rate that is effectively zero. This means that the valve will notdrip into the sampling bottle 34, it is either on or off. The fluiddevice 10 can accept multiple sampling valves, mounted in externalmodules to the main body 12/50, or mounted internally to the main body12/50. This optional configuration allows for the fluid device 10 toaccommodate multiple oil collection samples and store the filled bottles34 until conveniently able to collect. For example, if daily oil samplesare desired, but only collect the bottles 34 once per week, a fluiddevice 10 configured for 7 bottles 34 would meet this need. This wouldrequire that the main body 12/50 would accommodate 7 independentsolenoid actuated valves 19, sample bottle mounts 80, bottles 34, etc.,all aligned linearly within the oil path. Similarly, a 1-bottle fluiddevice 10 could be combined together with 6 additional single bottle 34add-on units (or 1 additional 6-bottle unit).

Sampling needle valves of solenoid 19 are interchangeable so thatorifice size can be varied, to accommodate different fluid viscosities.The fluid device 10 is specifically designed so that the sampling valvecan be replaced in a rapid and efficient manner.

An exemplary sample bottle 34 includes a high temperature rated 4.2 ozcapacity, clear PET bottles to accept hot oil samples without risk ofbottle degradation. Cleaned, sealed and sterile sample bottles 34 may beprovided directly from a factory to eliminate the risk of samplecontamination as a result of impure bottles.

The exemplary sample collection housing 18 of fluid device 10 provides asecure, lockable enclosure for fragile sample bottle 34 and other userinterface components. Furthermore, sample collection housing 18 providesfor controlled access to the programming port 93 and secure SD cardinterface, this serves to increase the tamper resistance of the fluiddevice 10. Sample collection housing 18 is a stainless steel (SS)enclosure (NEMA 4, IP67 rated enclosure) that is bolted to the undersideof the Lower Housing 50 utilizing the same shear lip functionalitymentioned previously. A custom shaped hole in the top surface of samplecollection housing 18 provides an interface with the CNC machinedsurface of the Lower Housing 50. Fasteners (SS screws with pre-appliednylon thread-locking compound) are installed from within the lockablemetal enclosure so as to prevent tampering from the outside of theenclosure by unauthorized personnel. Still further, the samplecollection housing 18 acts as a heat-sink by virtue of its extensive SSmetal mass and surface area aids in conductive heat transfer from theoil heated Lower Housing 50 (aluminum) thus cooling the main body 12/50.

The fluid device 10 has LED Light Windows in the Bezel 63 configured astransparent areas so that LED indicator lights can clearly andeffectively shine through. The clear LED windows are made by selectivelyapplying product labeling ink so as to create transparencies in theBezel 63 and these are aligned with each LED on a daughter board mountedto underside of Lid 40. Upper most surface of LED light pipe surfaces(for example 49 and 69) is positioned to within 0.005 in. of theunderside of the clear LED window to reduce the likelihood of scattering(diffusing) the light from the LEDs 49/69.

The fluid device 10 includes a LED Character Display. In one embodiment,the Lid 63 and Bezel 40 designs have LED/OLED display options forincreased flexibility of notification options. The LED display canfeature either high brightness 16-segment LED modules for alphanumericcharacter display, or a high brightness OLED (Organic LED) display formore detailed display capabilities. A clear LED display window isconstructed in Bezel 40 in the same fashion as the transparent windowsfor the LED light pipes.

The fluid device 10 includes at least one antenna window that allows theradio frequency signals necessary for Bluetooth® Communications topenetrate the lid 40. A radio-transparent plastic insert is installedinto the lid 40 in place of the aluminum material that makes up the topof the lid 40, with an approximate projected area of 0.5 in×1 in,between product labeling and the Bluetooth® antenna. The Bluetooth®antenna is mounted co-planar, on the top surface of the daughter board,very close to the underside of the lid 40. In combination with theradio-transparent antenna window, this allows an operator's smart deviceto communicate with the fluid device 10 when in close proximity to thetop of the lid 40. This configuration is for security reasons because itrequires close proximity to the fluid device 10 to function. In oneembodiment, located on the bezel 63 is a variety of system statusindicators that are linked to the core functions of the fluid device 10,for example, real-time data collection, oil sampling, dangerouscondition checking, add-on sensors, etc.

The printed circuit board assembly 111 (PCBA) of the fluid device 10includes a motherboard which is the main board and contains allessential electrical components and connectors that are required tocomplete the core functions of the fluid device 10. In one embodiment,the core functions include: oil sampling procedure, real-time datacollection, communications, data processing, dangerous conditiondetermination, and alerting. The PCBA/motherboard 111 also facilitatesexpansion ability.

The PCBA/motherboard 111 has a multilayer board design for spaceoptimization of component layout and ruggedness as the use environmentis continuous heat and vibration. The PCBA/motherboard 111 consists of a4-Layer laminated printed circuit board (PCB) with both surface mountdevice (SMD) and discrete through-hole components. Manufacturing andproduct information is printed on the outer surface of the PCB for easytracking of part number, revision, and date of manufacture. Furthermore,each PCB is serial numbered for traceability and lot control. Tracewidths on the PCB are extra wide (0.015 in.) with respect to theirthickness to facilitate reliable PCB-to-component solder joints in hightemperature, high vibration operation synonymous with an exemplaryapplication in the Oil and Gas Industry.

If the PCBA/motherboard 111 is to be sold/used in European Union (EU)countries, the PCBA/motherboard 111 can be made RoHAS compliant. If not,the solder used in the PCBA 111 is lead-based which allows for strongersolder joints.

The PCBA/motherboard 111 of the fluid device has a design/configurationthat allows for the addition of modular daughter boards to be added onto the assembly. This design/configuration allows for convenient andrapid functionality changes without the need for a complete PCBre-design. Consequently, because of this design/configuration, fluiddevice 10 can provide a diverse set of functions dependent uponapplication needs. Still further, modular daughter boards allow forquick change out to adjust for installation specific functions, i.e.indicator light layout, communication antenna, etc. Moreover, the headerconnector used to mechanically and electrically join the mother boardand daughter board provides conditioned power and a data bus between themating boards. Furthermore, the number of LEDs installed on a daughterboard can be varied depending on the product feature-set (i.e., add-onsensors).

As one non-limiting example, fluid device 10 can include a userinterface LED indicator light daughter board designed to present aseries of system status, operational condition, and/or warning lights(LED) to meet a specific application. The resulting daughter board mayinclude a dense matrix of LED light positions (i.e. 6 row×5 LEDs perrow=30 available LED positions) that are available for utilizationdepending on specific fluid device 10 application and productconfiguration. Once determined, the LED light position on the matrix ofthe available LED locations can be populated with appropriate LEDcomponents (soldered to the PCB) to customize the product, i.e., LEGO®fashion. The advantage of this pre-fabricated LED indicator light matrixdesign is the ability to rapidly configure the daughter board with acustom LED arrangement in order to offer an application-specific featureset.

LEDs are arranged for high visibility in high brightness environments.For example, one embodiment of the fluid device 10 features a uniquein-plane RF antenna design that incorporates several high brightness“SERVICE REQUIRED” LEDs for visibility in any condition. Vibrationresistant, high reliability board-to-board connector provides for signaltransfer and power between the two boards (motherboard and daughterboard of PCBA 111). Signal integrity is maintained by carefullydesigning the data transmission paths within the PCBA 111, as well asselecting high quality electrical connectors for the fluid device 10.

Mounting of the PCBA 111 for the fluid device 10 is provided for by theuse of machined in bosses on the underside of the Lid 40 surface thatspace the PCBA 111 adequately away in the vertical direction from theinner surface of the Lid 40 in order to provide clearance forcomponents, thus eliminating physical interference issues. Stainlesssteel (S.S.) mounting hardware (i.e., screws, lock washers) is used fordurability, longevity, and reliability. Self-locking fasteners (e.g.,NyLok®), or use of epoxy on the fasteners may be used to insurefasteners do not loosen over time as a result of cyclical thermal stressand/or vibration. Relatively large contact area between the PCBA 111ground pads and the mounting bosses integrally machined from theunderside of the Lid 40 will facilitate a greater conductive heat fluxinto the Lid 40, thus cooling the PCBA 111 more efficiently.

Attachment points for the PCBA 111 of the fluid device 10 utilizeintegrally machined aluminum mounting bosses which conduct heat awayfrom the PCBA 111 through the ground pads and out the external surfaceof the Lid 40 via natural convection of air movement over the fluiddevice 10. The mounting bosses (and mounting holes on the PCBA 111) arearranged in a non-standard, non-symmetrical fashion with respect to thegeometry of the PCBA 111. This physical geometry configuration minimizesthe potential for low frequency and high frequency harmonic vibrationsthat could resonate in the PCBA 111. Any harmonic resonances present inthe PCBA 111 could be very damaging to the integrity of the PCBA 111,for example, solder joints of the SMD components could fatigue thusallowing the components to “pop off” the board.

Due to the need for vibration resistance of the fluid device 10mentioned in the above paragraph, further design considerations for thefluid device 10 reduce the likelihood of vibration-related failures inthe PCBA 111. Multiple layers of copper (heavier copper weight) designedinto the multilayer PCBA 111 is employed so as to introduce additionalmass-dampening effects that will counteract the effects of vibrationrelated strains placed on the PCBA 111. In one embodiment, a 0.5-ozcopper layer is in the PCBA 111 of the fluid device 10. In anotherembodiment, a 4-oz copper layer is in the PCBA 111 of the fluid device10. In the embodiment with the 4-oz copper layer, the extra thick layerof copper will add mass and resistance to vibration-induced harmonics inthe PCBA 111.

Asymmetric mounting holes in the PCBA 111 of the fluid device 10 (asmentioned above) help to mitigate the risk of damaging harmonicresonances. Local potting (encapsulated) of key (heavy) components canbe employed to add additional stability and robustness to thecomponent-to-board solder joints. Lid 40 and PCBA 111 sub-assembly isdesigned to be completely encapsulated (potted) so as to mechanicallyand thermally couple the Lid 40 to the PCBA 111. This not onlyeliminates the risk of vibration related damage to the PCBA 111, it alsoenhances the conductive cooling of PCBA 111 components and adds anadditional level of tamper resistance. The full encapsulation alsoprovides a brute force approach to providing an “intrinsically safe”design to meet explosion proof rating.

The microprocessor of the fluid device 10 assigns both mathematicallyintensive and time sensitive tasks to a main processor, or CPU. In orderto optimally complete these tasks, both ARM and PIC based microprocessorplatforms have been considered. In one embodiment, the fluid device 10utilizes a 16-bit PIC microprocessor. In other embodiments, the fluiddevice 10 utilizes ARM microprocessors. The microprocessor is physicallylocated on the PCBA 111 as far away from high power, electrically noisycomponents as possible. This isolation design is intended to minimizethe effects of electromagnetic interference (EMI) and radio-frequencyinterference (RFI), thus increasing the overall reliability of theelectrical system.

The fluid device 10 operates on a 24 VDC input, which powers theSampling Valve Solenoid 19 as well as the high brightness status LEDs49/69. This 24V supply also powers a 12 VDC and a 3.3 VDC step downregulator to power all logic level components (i.e., microprocessor,sensors, communications, data storage devices). The 24 VDC input isheavily surge protected, over-voltage protected, and reverse polarityprotected for robustness. In one embodiment, all power managementsystems are designed per intrinsic safety best practices and standards.

Since the exemplary application for the fluid device 10 selected has hotoil, for example, 180-190° F., continuously circulating through it, allelectronics have to be selected to reliably operate in elevatedtemperatures. For this reason, board-mounted components have very highrated operating temperatures that range, at least, from about 221° F.(105° C.) to about 257° F. (125° C.). The fluid device 10 includes ahigh accuracy on-board temperature sensor used to measure thetemperature of the PCBA 111 in real-time to confirm that the electronicsare not overheating. Redundant critical-to-function on board sensorcomponents (i.e., accelerometer and temperature sensor) are utilized toensure proper function and to prevent false system alarms. In oneembodiment, component-to-board contact area is maximized to facilitateoptimal thermal continuity throughout the entire PCBA 111. Thisfacilitates the best possible conduction of heat out of the PCBA 111 andinto the Lid 40 where natural convection currents can shed heat.

Fluid device 10 includes sensitive digital (logic level) components suchas memory devices, the microprocessor, and associated electroniccomponents are located as far away as possible from radio transceiversand high power, electrically noisy and switching components. Thiselectronic component isolation design is intended to increase theoverall reliability of the electrical system for the fluid device 10.

The PCBA 111 of the fluid device 10 utilizes both unidirectional andomnidirectional antennas to support both Bluetooth® and 900 MHz RFcommunications. The Bluetooth® LE antenna is of the unidirectional typeand is mounted co-planar to the PCBA 111, on the top surface of thedaughter-board, on the surface facing the underside of the Lid 40, andaligned with a clearance hole machined in the aluminum to facilitate RFtransmissions directed up and out of the Lid 40. By optimizing thecomponent clearances and the dimensions of the mounting bosses(integrally machined from the aluminum Lid 40), the PCBA 111 ispositioned in a manner that allows for the Bluetooth® LE antenna to belocated very close (approximately 0.030 in.) from the underside of theLid 40.

The fluid device 10 includes a thin (0.062 inch thick) radio-transparentplastic (polycarbonate) sheet laminated and adhesively bonded to theouter surface of the Lid 40 with a permanent pressure sensitive adhesive(PSA) providing a weather sealed cover to the machined RF antennaopening in the aluminum Lid 40. This antenna configuration allows for asmart device (i.e., tablet, smartphone, etc.) to wirelessly communicatewith the fluid device 10 when the Bluetooth® LE device is in closeproximity to the top of the Lid 40. For security reasons, this is anoptimal configuration because it requires close proximity to the machinein order to wirelessly transmit data from the fluid device 10.

The 900 MHz antenna of the fluid device 10 is of the omnidirectionaltype. The fluid device 10 uses a board-mounted strip antenna (ref.Fractus S. A.) to communicate with other 900 MHz devices. The stripantenna is soldered to a dedicated PCB (Antenna Board) and is mountedperpendicular to the daughterboard via a connector. The antenna board isoptionally populated with high brightness LEDs that whenflashing/blinking can serve as a visual indication the RF transmissionis occurring. This strip-antenna/LED assembly is designed to protrudepast the top surface of the lid 40 and is protected by a transparentimpact resistant plastic (polycarbonate) shroud or dome that preventsimpact or vibration damage to the antenna.

The fluid device 10 includes a firmware stack that provides control forall of the functions performed by the fluid device 10 as well as thedata processing algorithms discussed more thoroughly subsequently. Thefluid device 10 functions both synchronously and asynchronously innature. The firmware handles both kinds of processing. Real-time dataacquisition (DAQ) and processing is constantly handled by the on-boardembedded processor. The firmware performs a large number of on-boarddata processing functions which enable it to detect a dangerous machinecondition (“Dangerous Condition”) and initiate a chain ofalerts/alarms/notifications so that the dangerous condition can beaddressed in real time.

Data gathered by the fluid device 10 is stored in a secure serverfacility and processed by powerful computing platforms to provide fleetwide analytics and performance metrics. An On-processor RAM is used forstoring data required for short term computations. In one embodiment,the PIC microprocessor is equipped with 53 KB of data storage. AnOn-board SRAM is used for storing all short term data that comes fromthe sensors or the microprocessor for writing to the ROM or FLASHstorage. The PCBA 111 is equipped with 256 KB of SRAM. An On-board ROMis used to store system configuration data and all required device IDinformation. The PCBA 111 is equipped with 1 KB of EEPROM. The Fluiddevice 10 includes a removable FLASH media and utilizes a secure andencrypted FLASH storage system, up to 16 GB capacity (ref. DataKey®,ATEK Access Technologies). Fleet-wide 30-sec data is aggregated bycommunications hardware and transmitted to a secure datacenter fordisplay and for further storage and processing.

The fluid device 10 is designed to maintain two time counts: 1)“Real-Time (RT);” and 2) “Machine-Time (MT).” Employing the dual timemanagement strategy provides the capability for intelligent machinehealth data that can be evaluated in terms of either: 1) the RT, as inthe calendar date and time, that is, year/month/day andhour:minute:second, that an event occurred; and 2) in terms of MT, theequipment operating lifetime (that is, 34,562 hours:26 minutes). MT canbe thought of similarly as the odometer in a motor vehicle, an officialDOT record of the cumulative number of miles the vehicle has experiencedin its history. Another comparison is with a Hobbs™ meter, a device usedin aviation to determine the cumulative number of hours (expressed inhours and tenths of an hour) an aircraft has been used.

Real-Time (RT) is maintained by an always-on, low power, high accuracyreal time clock (RTC). This RTC module is powered by a CMOS(complementary metal-oxide semiconductor) oscillator that is able tovery precisely maintain the current time value (that is, year/month/dayand hour:minute:second). As an extra level of precision control, thefluid device/system 10/120 is able to receive automatic time updatesfrom the atomic clock operated by NIST (National Institute of Standardsand Technology) via wireless communications with the internet connectedremote data and application server(s). This enables the fluid device 10in a fluid system 120 (FIGS. 14A-14B) to self-correct to clock driftthat is inherent to digital timekeeping methods, especially at elevatedtemperatures. Machine-Time (MT) is maintained in the fluid device 10using a combination of Oil Pressure sensing, dual redundant vibrationsensing and a heartbeat of the fluid device 10 which is coded to beevery 20 milliseconds (ms) in one embodiment. The combination of thesethree inputs allows the fluid device 10 to detect the operational stateof the machine/engine, that is, is the engine OFF or ON. The fluiddevice 10 will count the minutes and hours that the machine is detectedto be ON in order to maintain an operational time “Odometer” over thelife of the engine.

The fluid device 10 is able to communicate data and alert information toservers for enhanced functionality. An integrated RF 900 MHz radio(902-928 MHz ISM radio Band (ISM stands form Industrial, Scientific andMedical)) allows for wireless communication between the fluid device andexternal devices such as the data aggregator or other add-on sensors toprovide an overall fleet-wide picture of equipment health and operation.The fluid device 10 utilizes a wired Modbus (RTU or ASCII) link overRS485 (or TCP/IP) to communicate with the data aggregator which isinstalled on-site in an IP67 enclosure. This allows several fluiddevices 10 to be daisy chained together. This capability facilitatesefficient, easy installation with minimal duplicate wire-runs.

The fluid device 10 further includes a Bluetooth® LE (low energy ver.4.0) transceiver radio in the 2.40 to 2.48 GHz ISM radio band. OverBluetooth LE, the fluid device 10 can communicate with handheld smartdevices (i.e. tablets, smartphones, etc.) for more effective managementof fluid device 10 settings. The Bluetooth LE connection also enablesseamless management of the workflow surrounding oil sample collection asuse of a fluid device 10 mobile application to tag oil sample bottleswith an appropriate ID and generate shipping information needed to sendthe samples to the laboratory.

Referring to FIGS. 1-14, the fluid device 10 employs a series of in situdigital and analog sensors (at least sensors 19 and 70) that arepositioned in the recirculating oil path (flow path) 71 (FIGS. 3A and3B) which is machined into the Upper housing 12 and Lower housing 50.The arrangement of these sensors 19/70 is linear along the path 71. Thesensor bodies 19/70 are threaded into the machined aluminum UpperHousing 12 and incorporate an oil resistant seal to prevent leaking ofthe engine oil that is coursing through the oil path 71 at high pressure(ranging from at least about 45 psi to about 80 psi) as provided by theengine 15 (FIG. 14A) driven oil pump. An exemplary, non-limiting engine15 is a Caterpillar G3616 TALE˜natural gas fired, 16-cylinder,turbo-assisted, lean burn efficiency. The active sensor tip or sensorcage (element) (for example, 101 of fluid property sensor 70) (FIGS. 3Aand 3B) is positioned in a manner as to be subjected to the flow 73/78of the oil at an angle of about 90°, or perpendicular to the axis of theoil flow 73/78. The sensor signal output is facilitated by connectingthe sensor data wires to the printed circuit board assembly 111 (PCBA)affixed to the underside of the Lid 40 which is situated just aboveUpper Housing 12 and contained in the Lid 40.

The engine 15 driven oil pump delivers an oil flow rate, in oneembodiment, in excess of 300 gallons per minute (GPM). The galley porton the engine block that the fluid device 10 is tapped into is one ofthe high-flow, high pressure ports. This is advantageous in that a highflow rate flowing across the sensor tips presents a constant flow offresh oil that is turbid 73/75/77/78 (as opposed to a laminar flow) withhomogeneously mixed contaminates. This is preferred over the alternativeof a slow flow, laminar flow, that may deliver erratic pulses of highconcentrations of contaminates which could bias the real-time sensingresults. Furthermore, a low flow rate with laminar flow (low shearforces in both the axial and transverse flow direction) could facilitate“plate out” or varnish formation on the sensor tip surfaces which wouldbias the sensor measurements, or even render the sensor output invalid.To prevent this creation of varnish, the design of the oil flow path 71in the Upper and Lower Housings 12/50 of the fluid device 10 was createdin a manner that would maximize the non-laminar (or turbid) motion73/75/77/78 of the oil flow 73/75/77/78, thus creating a flow streamthat exhibits high shear forces in both the axial and transverse flowdirections. This is referred to as a “self-scouring” design.

In one embodiment, the fluid property sensor 70 has a sensor body thatis made of 316 stainless steel (SS) and is IP68 rated. The temperaturedata unit of measure is ° C. (degrees Celsius). An exemplary Fluidtemperature range of measurement by fluid property sensor 70 is about−40° C. to about 150° C. Fluid. The fluid device 10 is programmed toupdate temperature data at 30 second intervals. However, other updateintervals are possible, such as, every 5 seconds, and a range ofpossible update intervals include 5 seconds to 60 seconds and includingeach integer in between (for example, every 6 seconds, 7 seconds, 8seconds, 9 seconds, 10 seconds . . . to every 60 seconds). In oneembodiment, the digital output is per J1939, CAN2.0B standard or CAN2.0Afeaturing high-resolution parameter readings. The fluid property sensor70 is connected to the PCBA 111 (located in Lid 40) via a 4-pin FCIstyle Molex® connector.

The fluid property sensor 70 of fluid device 10 measures fluid viscosity(in this example, oil viscosity). Viscosity is a measure of fluidresistance to flow and is informally referred to as the “thickness” of afluid. For example, at the same temperature, maple syrup has a muchhigher viscosity than water. The viscosity of a fluid is highlysensitive to temperature, that is, syrup at a higher temperature is“thinner,” less resistant to flow, and therefore, less viscous than whencompared to syrup at room temperature.

Dynamic Viscosity of oil is measured by the digital fluid propertysensor 70. For dynamic viscosity data, the SI unit of measure is mPa-s(centipoise ˜cP). In one exemplary embodiment, the fluid property sensor70 measures Dynamic Viscosity ranging from about 0.5 to about 50 cP.Dynamic Viscosity data update interval is 30-seconds. Digital output ofthe fluid property sensor 70 is as per J1939, CAN2.0B standard orCAN2.0A protocols featuring 16-bit parameter readings. The fluidproperty sensor 70 is connected to the PCBA 111 via a 4-pin FCIAutomotive style connector, that is, Delphi® and/or Molex®.

Based on an algorithm to be discussed/presented subsequently, thedynamic viscosity output is temperature corrected to determine if themeasured value from the fluid property sensor 70 is within the acceptedthreshold limits of the Society of Automotive Engineers (SAE) grade ofoil used in the application (e.g. SAE 40). Utilizing a controlled labenvironment and per industry accepted ASTM protocols, the dynamicviscosity of virgin engine oil (Mobil Pegasus 805®) was fullycharacterized across a wide range of known engine operatingtemperatures. The resulting temperature-viscosity curve (shownsubsequently) for the subject oil was analyzed using nonlinearregression analysis methods to solve for a math-based algorithm whichcharacterizes the viscosity-temperature relationship for the oil withinthe range of known engine operating temperatures. This algorithm allowsone to reliably determine the expected (virgin) dynamic viscosity valueof the engine oil anywhere along the temperature spectrum. The algorithmis embedded into the firmware and is used to process the raw dynamicviscosity from the fluid property sensor 70 in order to determine acurrent status, dangerous condition, and/or useable life of the oilbased on the temperature corrected viscosity value.

As a point of reference, the temperature based viscosity values asreported on manufacturer product data sheets are reported at only two(2) temperatures, 40° C. and 100° C. This is also true of industryrecognized ASTM test protocols (ASTM D445) used by in-house andindependent labs to determine the oil's viscosity properties. However,it is important to note that the temperature-viscosity curve of anyfluid between the two (2) temperature extremes (40° C. and 100° C.) willNOT be linear. As a result of this fact, the resulting curve fit to themeasured data is non-linear. The importance of this discovery is that itwould be unwise and incorrect to determine the health and/or useful lifeof a lubricant based on the assumed linear behavior of the oil with atemperature measured between the commonly referenced extremes (40° C.and 100° C.).

The fluid device 10 and fluid system 120 is configured to output thefollowing required data:

Dynamic viscosity value (cP): 16-bit value directly measured by thefluid property sensor 70, value updated every 30-seconds;

Density value (gm/cc): 16-bit value directly measured by the fluidproperty sensor 70, value updated every 30-seconds;

Kinematic viscosity value (cSt): is calculated by utilizing the OilDensity (measured by fluid property sensor 70), computational formulasare embedded in firmware, value updated every 30-seconds; and

Relative viscosity-based condition of the oil: value expressed as apercentage (%) of useful SAE Range, developed computational formulas areembedded in firmware, value updated every 30-seconds.

Consider the following as a representative example (SAE 40 Grade). PerSAE standards, a Grade 40 oil can exhibit a viscosity of 12.5 cP to<16.3 cP and still be considered useable. However, if the oil exhibitsan increased resistance to flow such that its viscosity becomes greaterthan 16.3 cP (>16.3), it has exceeded the upper specification limit forSAE 40 oil and slips into the SAE 50 range (or higher). Correspondingly,if the oil is thinner and measures less than 12.5 cP (<12.5), the oilwould be classified as a SAE 30 Grade (or lower). The consequences ofoperating the subject equipment (engine, compressor, etc.) with anoff-spec oil (thinner or thicker) would likely cause damage to theequipment, shorten the useful life of the equipment, and/or potentiallylead to a catastrophic equipment failure.

The novel fluid device 10 and fluid system 120 approach to temperaturecorrecting the measured oil viscosity in order to compare it against a“nominal baseline” will provide the operator with a more dynamic,accurate and actionable set of real-time data that can contribute tohigher equipment reliability and lower overall operating costs ofmaintaining the physical asset.

The fluid device/system 10/120 collects real-time viscosity (dynamic)data by the fluid property sensor 70 and is timestamped both in terms ofmodified Julian date (MJD) (i.e. year:month:day:hour: minute:second) andin terms of equipment operating lifetime (i.e. 34,562 hours:26 minutes).During an oil sample collection event (schedule-based routine oil sampleor sample-by-exception oil sample initiated by the detection of aDangerous Condition event), the 4-oz bottle 34 receives sample oil andis ultimately sent off to a lab for further analysis. The samplingbottle 34 also has both timestamps (MJD and Engine lifetime) associatedwith the solenoid 19 actuated valve opening event. Comparison of theelectronic viscosity data value from the fluid property sensor 70 andthe ATSM protocol lab analyzed viscosity data value from the oil samplecan provide an opportunity to recalibrate the fluid property sensor 70mounted on the engine 15. This re-calibration of the electronic fluidproperty sensor 70 can be autonomously performed on a continuous basisthrough the utilization of a custom developed API between the oilanalysis lab database of the fluid device 10 database.

The fluid device/system 10/120 collects real-time dielectric constantdata. A dielectric constant of a material is a measure of its ability totransmit electrical potential energy. The dielectric constant is asimple number that is the relative ratio of the speed of an electricfield in a material compared to the speed of the electric field in avacuum. When the dielectric constant of a lubricating oil is measured,changes in the dielectric constant of the used oil compared to new oilmay indicate the presence of contaminants, such as water or particles,or changes in chemistry of the oil such as additive depletion oroxidation.” (Machinery Lubrication, The Dielectric Constant and OilAnalysis, A. A. Carey, et al (September 2001)).

The dielectric constant of the oil is measured by the digital fluidproperty sensor 70. Dielectric Constant data SI unit of measure isunit-less. The Dielectric Constant measurement range of the MS85C isabout 1.0 to about 6.0. The Dielectric Constant data update interval is30-seconds by the fluid device/system 10/120. Digital output is as perJ1939, CAN2.0B standard or CAN2.0A featuring high-resolution parameterreadings. The fluid property sensor 70 is connected to the PCBA 111(located in Lid 40) via a 4-pin FCI style Molex® connector.

The fluid device/system 10/120 collects real-time density data of theoil flowing through the fluid device 10 by the fluid property sensor(FPS) 70. Density data SI unit of measure is grams per cubic centimeter(gm/cc). Oil Density measurement ranges by the FPS 70 is about 0.65 toabout 1.50 gm/cc. The Density data update interval is 30-seconds.Digital output is as per J1939, CAN2.0B standard or CAN2.0A protocolfeaturing high-resolution parameter readings.

The fluid device/system 10/120 collects real-time oil pressure data ofthe oil flowing through the fluid device 10 by the fluid pressure sensor(referenced generally with numeral 70 same as FPS) which is a componentof the Sensor package 70 which also includes the fluid property sensor(FPS). In one embodiment, the fluid pressure sensor is an analogpressure transducer. It should be understood that in one embodiment, arepresentative fluid pressure transducer can be purchased fromMeasurement Specialties™ having an internet address of www.meas-spec.comand is a separate structure from the fluid property sensor 70. As aseparate structure, pressure transducer is provided in a separate portin lower housing 50 from fluid property sensor 70, such as port 117shown in FIG. 13. A specific representative fluid pressure transducer islisted as Model 85-100G-4C.

An exemplary fluid pressure sensor can be made of 316 stainless steel(SS) and is IP68 rated. Pressure data is in SI units of measure which ismPa-s (centipoise ˜cP). Digital output is as per J1939, CAN2.0B standardor CAN2.0A featuring high-resolution parameter readings,

The FPS 70 of the fluid device/system 10/120 collects real-time watercontent data of the oil flowing through the fluid device 10. Anexemplary method of determining the water content includes the fluiddevice/system 10/120 utilizing the dielectric constant measurement fromthe FPS 70 described above. The dielectric constant measurement inconjunction with an algorithm (described subsequently) which is embeddedin the microprocessor is used to determine the amount of watercontamination (water content) in the oil.

Real-time measurement or determination of water content provides thereal-time capability to detect engine coolant (water/glycol) that isleaking into the oil system of the engine 15. Such leakage would rapidlycompromise the integrity of the engine oil, and therefore, rapidlycompromise the integrity of the engine. Such real-time capability tomeasure water content in the oil system provides the opportunity toprevent a likely catastrophic engine failure if the leak was leftundetected and unattended. Water Content data SI unit of measure isparts per million (ppm). Water Content measurements range from about 200ppm to about 2000 ppm. Water Content data update interval is 30 seconds.

Based on the algorithm mentioned above, the Dielectric Constant datavalue was outputted from the FPS 70 which was measured from a controlledsample of virgin engine oil (Mobil Pegasus 805®) after carefullytitrating a known weight percent (wt %) of a water/glycol solution thatwas added to purposely contaminate the oil sample. The water/glycolmixture was prepared as a 50/50 mix of deionized water and antifreeze(glycol) to simulate a typical engine coolant. Utilizing a controlledlab environment and per industry accepted ASTM protocols (ASTM D6304A),the Dielectric Constant value of the water/glycol contaminated engineoil was fully characterized across a wide range of known engineoperating temperatures. The resulting large database of measuredDielectric Constant data values were analyzed using digital signalprocessing (DSP) methods to determine a math-based algorithmcharacterizing the Dielectric Constant-Coolant Contaminationrelationship, thus being able to reliably determine the water/glycolcontamination level anywhere along the Dielectric Constant spectrum. Thealgorithm is embedded into the firmware library of the microprocessorand is used to data process the raw fluid property sensor 70 output inorder to determine a current status, Dangerous Condition, and/or useablelife of the oil based on the Dielectric Constant value.

Moreover, the Water Content data collected by the fluid device/system10/120 in real-time by the FPS 70 is timestamped (i.e.year:month:day:hour: minute:second). During an oil sample collectionevent (schedule-based routine oil sample or sample-by-exception oilsample initiated by the detection of a Dangerous Condition event), the4-oz bottle 34 of sample oil collected and sent off to a lab for furtheranalysis also has a timestamp associated with the solenoid 19 actuatedvalve opening event. Comparison of the electronic Water Content datavalue (from FPS 70) and the ATSM protocol lab analyzed Water Contentdata value can provide an opportunity to recalibrate the FPS 70.

The fluid device/system 10/120 has the capability to detect equipment(in this case engine 15) ON/OFF status in real-time. That is, inreal-time determine if the equipment (engine, compressor) is actuallyoperating. A Dangerous Condition alarm notification would be generatedif the equipment was confirmed to be non-operating. This is importantfor equipment such as natural gas compression equipment (gathering gas,gas processing, gas transmission applications), which are designed tooperate on a 24/7/365 basis, were such equipment to suddenly experiencea shutdown event.

The capability to detect equipment ON/OFF status is by utilizing a PCBA111-mounted accelerometer and the Oil Pressure value from the FPS 70 tomake a determination that the equipment has experienced a shutdownevent. A Dangerous Condition algorithm is embedded in the firmware ofthe microprocessor. The Algorithm contains a routine that looks for aminimum of four (4) consecutive 30-second Oil Pressure values (total of2 minutes) to minimize the possibility of a false positive which wouldresult in an inaccurate alarm notification. Each ON or OFF event iscaptured and logged in the database maintained on a secure remoteserver. Still further, equipment OFF duration and frequency is logged toprovide Equipment Uptime, a key performance indicator (KPI) metricclosely managed.

If the real-time monitored Oil Pressure value were to suddenly go tozero while the accelerometer measured constant vibration, the possiblescenario is that the oil line to the fluid device 10 has beencompromised and is likely leaking and/or spewing oil all over the place.Conversely, if the Oil Pressure measure is positive and theaccelerometer is negative, it would indicate that the PCBA 111-mountedaccelerometer has failed and needs to be replaced or re-calibrated.

The fluid device/system 10/120 has the further capability that couplesthe real-time measurement of oil quality with physical oil samplecollection for further oil measurement of oil quality, typically in acontrolled lab environment and per industry recognized ASTM protocols,and comparing the real-time quality measurement with the qualitymeasurement of the sampled oil in the lab.

Proprietary Algorithm for Real-Time Temperature Correction of Engine OilViscosity

In order to develop the Algorithm for Real-Time Temperature Correctionof Engine Oil Viscosity for the Fluid Device/System 10/120, anexperiment was conducted to determine the effects of oil temperature onoil viscosity in virgin engine oil. The motivation to carry out thisexperiment was the need for real-time temperature correction in theFluid Device/System 10/120 as well as lack of data in ASTM D445documents.

This experiment was carried out in two stages, the first being thelaboratory experiment designed to produce the empiricaltemperature-viscosity data for virgin engine oil (Mobil Pegasus 805®)and the second being the regression analysis performed to obtain thetemperature-viscosity algorithm for the Fluid Device/System 10/120.

Stage—1: Baseline Oil Viscosity Recording

Define oil temperature range for the experiment based on data providedin engine OEM specification and ASTM D445 standard. Record baselinedynamic viscosity values (units: cP) for the engine oil at fixed oiltemperature intervals spaced evenly within the defined range.

a. Experimental Apparatus

-   -   250 ml Pyrex® glass beaker    -   500 ml Pyrex® glass beaker    -   200 ml virgin engine oil    -   Hot Plate with magnetic stir bar & temperature probe attachment    -   Measurement Specialties FPS 2800 Fluid Property Sensor with        Arduino-based data acquisition device    -   Ring stand    -   Ring clamp

b. Methodology

The 250 ml beaker is placed on the hot plate inside of a 500 ml beakerthat is filled with water to provide even heating of the oil sample.Virgin engine oil is poured into the 250 ml beaker. The temperature ofthe oil is precisely controlled using the hot plate's temperature probeattachment which provides feedback to the hot plate's internaltemperature controller. The fluid property sensor element (FPS 70) isimmersed in the oil using the ring stand and ring clamp. The fluidproperty sensor (FPS 70) measures oil properties such as oiltemperature, dynamic viscosity, density and dielectric constant and ittransmits the measured data over the CAN (Controller Area Network) busprotocol. The Arduino data acquisition device is configured to capturethis data into a log file which can be read into the computer forfurther analysis. In order to produce high quality data, for each oiltemperature value, multiple viscosity values were tabulated to removehuman and experimental errors.

c. Experimental Results

The resulting scatter plot of Oil Temperature in Celsius vs. DynamicViscosity is shown in FIG. 24. As expected, oil viscosity decreases withincreasing oil temperature (e.g.: hot maple syrup flows easily comparedto cold syrup). Since precision temperature control was adopted,viscosity values appear as a stack at each oil temperature value. Also,the utilization of a precision temperature control served to greatlyreduce noise in the data and eliminate outliers. This data is then usedin the second stage of the experiment where a curve fit equation isderived.

Stage—2: Baseline Oil Viscosity Curve Fitting

In order to develop the Algorithm for Real-Time Temperature Correctionof Engine Oil Viscosity for the Fluid Device/System 10/120, a curve fitequation is derived to describe the experimentally collected data inStage 1.

a. Methodology

From the scatter plot (FIG. 24), it is clear to the casual observer thatthe data is non-linear, that is, it appears less as a straight line andmore as a curve. The process of evaluating a set of data points andderiving a curve is known as regression. In this case, since the data isnon-linear, the optimal regression method is non-linear regression.

The quality of curve-fit is decided by two factors:

-   -   Factor 1—Goodness of curve fit: This is indicated as r² and is        termed statistically as co-efficient of determination. The        closer r² value is to 1 (or 100%), the better is the curve fit.    -   Factor 2—Performance of the curve within the OEM specified        temperature range: The performance of an ideal curve would be no        bias (or swing) towards extreme values at a given oil        temperature. Ideally, the curve should pass through the average        (or mean) value of oil viscosity at each oil temperature. A        perfect curve for the dataset would exactly represent the        behavior of the dynamic viscosity of the specified oil type at a        given temperature value.

b. Results

The highest performing derived curve for the baseline viscosity valuesis as shown in FIG. 25.

The derived curve-fit equation can be represented in a mathematicalformat shown in Equation 1.

μ=(a+b/T ²)²  Equation 1

Here,

-   -   μ is dynamic oil viscosity in cP    -   T is oil temperature in Celsius.    -   a & b are curve-fit coefficients which decide the shape of the        curve. Their values are, respectively: 1.5763649 and 17018.976.

Conclusion:

-   -   Equation 1 is used in fluid device/system 10/120 firmware to        correct oil viscosity values in real time with respect to        changes in oil temperature.    -   The Goodness of Fit (or r²) for the selected equation was found        to be 99.758%, which implies the accuracy of the curve fit is        high.    -   The mathematical simplicity of Equation 1 allows for a robust        implementation on the fluid device/system 10/120 embedded        platform. The relative simplicity helps to eliminate numerical        errors such as rounding off and truncation of the calculated        values due to the nature of embedded platforms.

Algorithm for Temperature Correction for Dielectric Constant

Water Content—the fluid device/system 10/120 utilizes the DielectricConstant measurement from the fluid property sensor 70, in conjunctionwith a custom developed algorithm (see FIG. 16) embedded in themicroprocessor to determine the amount of “free” water contamination inthe oil. An interest exists in the ability to detect engine coolant(mixture of water and ethylene glycol) leaks in real-time, a conditionthat would rapidly compromise the integrity of the engine oil if leftun-checked. Such a real-time water detection capability would allowoperators to prevent a catastrophic engine failure that would have beenleft undetected and unattended without the fluid device/system 10/120.

Dielectric Constant measured by the digital fluid property sensor 70.Through the use of the Algorithm, dielectric constant data andtemperature data are converted into the water contamination in oil asexpressed in parts-per-million (ppm).

An algorithm, the result of laboratory experiments, uses dielectricconstant data and temperature data provided by the fluid property sensor70 to determine the water content of oil on 30-second intervals. Thewater content value is then used to issue WARNING or DANGER alarms ifthe value is calculated to exceed “safe” operating condition thresholds.

The exact threshold values are set by the engine (or compressor)manufacturer. Example of a DANGER threshold (also referred to as a‘condemning limit’ by OEM manufacturers) for a Caterpillar 3600 seriesengine is 5000 ppm for water and 0 ppm for ethylene glycol.

Water Content data SI unit of measure is parts per million (ppm). WaterContent measurement range of the fluid property sensor 70 used in thefluid device/system 10/120 is 200 to 600 ppm. Through the addition of asecond water detection sensor that measures “saturated” water (vs. freewater) in oil, (for example, an HTM2500 sensor sold by MeasurementSpecialties), the water-in-oil detection range can be extended to 2000ppm. Water Content data update interval is 30-seconds.

Based on the algorithm, the Dielectric Constant output from the fluidproperty sensor 70 was measured from a controlled sample of virginengine oil (Mobil Pegasus 805®) after carefully titrating a known volumepercent (vol %) of a water and ethylene glycol solution was added topurposely contaminate the virgin oil sample. The water/ethylene glycolmixture was prepared as a 50/50 (vol %) mix of deionized water andantifreeze (ethylene glycol) to simulate a typical engine coolant.Utilizing a controlled lab environment and per industry accepted ASTMprotocols (ASTM D6304A), the Dielectric Constant values ofwater/ethylene glycol contaminated engine oil (Mobil Pegasus 805®)across a wide range of expected engine operating temperatures (150° F.to 200° F.) were fully characterized. The resulting large database ofmeasured Dielectric Constant data values were analyzed using statisticalsignal processing methods to develop an algorithm for characterizing theDielectric Constant-Water Contamination relationship, thus enabling thecapability to reliably determine the volume amount of water/ethyleneglycol contamination present in a given sample of oil. The developedalgorithm is embedded into the firmware and is used to process the rawfluid property sensor 70 output in order to determine a currentoil-water contamination status, identify the presence of a DangerousCondition based on water content, and/or calculate the useable life ofthe oil based on the Dielectric Constant value.

Real-time sensor derived Water Content data vs. lab derived:

The Water Content data produced by the fluid device/system 10/120 fromthe real-time fluid property sensor 70 output is timestamped both interms of modified Julian date (MJD) (i.e. year:month:day:hour:minute:second) and in terms of equipment operating lifetime (i.e. 34,562hours:26:minutes).

During an oil sample collection event (schedule-based routine oilsample, manual sample or sample-by-exception oil sample initiated by thedetection of a Dangerous Condition event), the 4.2-oz oil sample bottle34 is filled and sent off to a laboratory for further analysis. Thesample event also has both MJD and MT timestamps associated with theprecise instant that the solenoid 19 actuated valve opening eventoccurred.

Comparison of the electronic Water Content data value (from the fluidproperty sensor 70 of fluid device/system 10/120) and the ATSM protocollab analyzed Water Content data value can provide an opportunity torecalibrate the mounted electronic fluid property sensor 70 if required.

Fluid Monitoring and Management System

An exemplary, non-limiting, fluid monitoring and management system 120,while previously mentioned, is now described more thoroughly accordingto one of various embodiments of the invention.

Referring to FIGS. 14A and 14B, the fluid device 10, as previouslyextensively described, is incorporated into fluid system 120 accordingto one of various embodiments of the invention. A supply line 17provides fluid communication between a fluid system of a subject machineor equipment and the fluid pathway 71 (FIGS. 3A and 3B) of fluid device10. In one non-limiting embodiment as stated previously for thisdocument, the fluid system is an oil system of an engine 15. In oneembodiment, fluid device 10 is mounted directly to the subject machineor equipment. In one embodiment, fluid device 10 is mounted remotelyfrom the subject machine or equipment. Supply line 17 allows oil to exitfrom engine 15 and to enter fluid device 10. A return line 61 providesfluid communication with the oil system of engine 15 and the fluidpathway 71 of fluid device 10. Return line 61 allows oil to exit fromfluid device 10 and to reenter engine 15. Fluid device 10 includes auser interface 66 (system status indicator (LED)).

Wired connection 63 provides electrical/data communication betweenelectrical components of fluid device 10, for example, the printedcircuit board assembly 111 (PCBA), and a data aggregator/communicationshub 65. Data aggregator/communications hub 65 is in electrical/datacommunication with a wireless receiving/transmission system 67. In oneembodiment, the data aggregator/communications hub 65 cansupport/accommodate 1 to 8 fluid devices 10. In one embodiment, the dataaggregator/communications hub 65 can support/accommodate more than 8fluid devices 10. Wireless receiving/transmission system 67 providescellular and satellite connectivity to any remote site capable ofreceiving radio waves. Consequently, this connectivity allowselectrical/data communication (signal communication) (radio waves)between the fluid device/system 10/120 and any remote site.

For example, referring to FIG. 14B, the electrical/data communication(signal communication) (radio waves) from wirelessreceiving/transmission system 67 is received by repeater 121 andtransmitted to, and received by, ultimately, the internet 122 (and/or“cloud”). From internet 122, electrical/data communication istransmitted to, and received by, a remote data server 123 (that is, backend layer 126). In one embodiment, remote data server 123/back end layer126 includes access to/communication with at least one or more databases(DB). For example, remote data server 123/back end layer 126 includes:an exemplary first database DB1 127 that includes MySQL Streaming Data;an exemplary second database DB2 128 that includes NoSQL Streaming Data(Anonomized); an exemplary third database DB3 130 that includes SQLPre-processed Data; an exemplary fourth database DB4 131 that includesSQL Header Data (Encrypted); and an exemplary fifth database DB5 129that includes SQL Entitlements.

Databases DB1 to DB5 can individually, or collectively, access and/orcommunication with a data access layer 124 such as a remote applicationserver 124. Data access layer/remote application server 124 can beconfigured to be customer specific/customer developed and comprise, as anon-limiting example, predictive analytics, data processing and datacorrelation.

The data access layer/remote application server 124 can individually, orcollectively, access and/or communication with a front end layer (remoteOutput Server) 125 such as a graphical user interface (web dashboard).In one embodiment, the front end layer/graphical user interface/remoteOutput Server 125 includes as a non-limiting example, a Client ERPsystem 133 that can access and/or communication with maintenance workorders, business metrics, etc., 139. The front end layer/graphical userinterface 125 can further include Dashboard (website) 134; bestpractices, statistical output 138; Dashboard (mobile) 135; documents137; and reports 136.

Fluid Monitoring and Management Methods

Using the inventive fluid monitoring and management device 10 and system120 described previously throughout this document, the following variousinventive, and non-limiting, fluid monitoring and management methods canbe implemented and are now described.

An exemplary one non-limiting fluid method 200 includes Performing aDangerous Condition Check 200. Referring to FIGS. 15A and 15B, the fluiddevice/system 10/120 can identify harmful lubricant conditions ormachine failures. Performing a Dangerous Condition Check 200 includesthe following method steps:

Method step 202: The fluid device/system 10/120 performs a “dangerouscondition” check every thirty seconds in order to determine if a sensorinput has reached (and surpassed) a threshold value.

Method step 204: The fluid property sensor 70 installed in situ withinthe fluid device/system 10/120 measures several parameters of the fluidflow and stores the measurement data on a data storage device (e.g. RAM)located on the PCBA 111. This measurement process occurs every 30seconds.

Method step 206: In situ sensor inputs by Fluid device/system 10/120include: 1) Fluid Pressure, 2) Fluid Temperature, 3) Dynamic Viscosityof the fluid, 4) Dielectric Constant of the fluid, 5) Density of thefluid.

Method step 208: Upon the FIRST sensor measurement (after 30 secondshave elapsed), measure all fluid property values (method step 206) andcompare the values against threshold value settings to see if any ofmeasured values have exceeded the thresholds.

Method step 210: If no threshold value settings are exceeded, there isnot likely to be a “Dangerous Condition” present.

Method step 212: Since all measured fluid properties were identified tobe within acceptable threshold(s), return to method step 202 and repeatthe process again after 30-seconds have elapsed.

Method step 214: If one or more thresholds are exceeded, there is apotential “Dangerous Condition.” The Dangerous Condition Process willthen assign the FIRST strike to each value that exceeds a threshold.

Method step 216: For the SECOND time, the fluid property sensor 70installed within the fluid device/system 10/120 measures severalparameters of the fluid flow and stores them on a data storage devicelocated on the PCBA 111. This happens every thirty seconds.

Method step 218: perform method step 206.

Method step 220: Upon the SECOND sensor measurement (after 30-secondshave elapsed), measure all fluid property values and compare themagainst threshold values to see if any of them are still exceeded.

Method step 222: If all measured values are within expected parameters,there is not likely to be a Dangerous Condition present.

Method step 224: Since all measured fluid properties were identified tobe within acceptable threshold(s), return to method step 202 and repeatthe process again after 30-seconds have elapsed.

Method step 226: If one or more of the SAME thresholds are exceeded fortwo consecutive cycles, there is a potential Dangerous Condition. TheDangerous Condition Process will then assign a SECOND strike to eachvalue that exceeds a threshold. If one or more new thresholds areexceeded, assign a FIRST strike to those values.

Method step 230: For the THIRD time, the fluid property sensor 70installed within the fluid device/system 10/120 measures severalparameters of the fluid flow and stores them on a data storage devicelocated on the PCBA 111. This happens every thirty seconds.

Method step 232: perform method step 206.

Referring to FIG. 15B, Performing a Dangerous Condition Check 200continues with the following method steps:

Method step 234: Upon the THIRD sensor measurement (after 30-secondshave elapsed), measure all fluid property values and compare themagainst threshold values to see if any of them are still exceeded.

Method step 236: If all measured values are within expected parameters,there is not likely to be a Dangerous Condition present.

Method step 238: Since all measured properties were identified to bewithin acceptable threshold(s), return to method step 202 and repeat theprocess again after 30-seconds have elapsed.

Method step 240: If one or more of the SAME thresholds are exceeded,there is a potential Dangerous Condition. The Dangerous ConditionProcess will then assign a THIRD strike to each value that exceeds athreshold. If one or more new thresholds are exceeded, assign a FIRSTstrike to those values.

Method step 242: For the FOURTH time, the fluid property sensor 70installed within the fluid device/system 10/120 measures severalparameters of the fluid flow and stores them on a data storage devicelocated on the PCBA 111. This happens every thirty seconds.

Method step 244: Fluid device/system 10/120 sensor inputs include: 1)Fluid Pressure, 2) Fluid Temperature, 3) Dynamic Viscosity of the fluid,4) Dielectric Constant of the fluid, 5) Density of the fluid.

Method step 246: Upon the FOURTH sensor measurement (after 30-secondshave elapsed), measure all fluid property values and compare themagainst threshold values to see if any of them are still exceeded.

Method step 248: repeat method step 236.

Method step 250: repeat method step 238.

Method step 252: If one or more of the SAME thresholds are exceeded,there is a potential Dangerous Condition. The Dangerous ConditionProcess will then assign a FOURTH strike to each value that exceeds athreshold. If one or more new thresholds are exceeded, assign a FIRSTstrike to those values.

Method step 254: All values with thresholds that have been exceeded forFOUR consecutive times (FOUR strikes) measured over four (4) consecutive30-second cycles (total elapsed time of two (2) minutes) are taken to beindicators of the presence of one or more Dangerous Conditions, one foreach threshold exceeded.

Method step 256: Utilize the threshold definitions stored on the fluiddevice/system 10/120 to determine if each Dangerous Condition isrepresentative of a WARNING Condition (Less Severe) or a DANGERCondition (More Severe).

Method step 258: If there is a DANGER Condition present, initiate an“exception-based,” autonomous oil sample collection event, blinkappropriate SmartOil system status indicator light(s), and send DANGERalarm notifications (that is, SMS (short message service) text message,email, auto-attendant phone call(s), etc.).

Method step 260: If there is a WARNING Condition present, blinkappropriate fluid device/system 10/120 status indicator light(s), andsend WARNING alarms (i.e. SMS text message, email, auto-attendant phonecall(s), etc.).

Referring to FIG. 16, another exemplary non-limiting fluid method 300includes Temperature Correcting Oil Dielectric Constant Measurements300. The fluid device/system 10/120 is capable of eliminating theeffects of temperature changes to dielectric constant measurements anddetermining the real departure of an oil's dielectric constant from theoil's baseline (virgin) dielectric constant. Performing a TemperatureCorrecting Oil Dielectric Constant Measurements 300 includes thefollowing method steps:

Method step 302: The fluid device/system 10/120 utilizes the in situfluid property sensor 70 to measure the Temperature and DielectricConstant of the fluid every 30-seconds.

Method step 304: The fluid property sensor 70 inputs include: 1) FluidTemperature, 2) Dielectric Constant of the fluid.

Method step 306: The fluid device/system 10/120 applies the mathematicalfunction for temperature correction of dielectric constant, where theinputs are defined in method step 304. This function is specificallyderived in the laboratory for a given manufacturer, SAE grade, and/orformulation of hydrocarbon based lubricant. Bd=Baseline DielectricConstant; T=Oil Temperature in degrees Celsius;Bd=exp(0.8226736+(−6.1007466×1 e-6×T×T)).

Method step 308: The fluid device/system 10/120 system is able toproduce the temperature corrected dielectric constant in terms of “% OFNEW,” thereby allowing for the identification of harmful oil propertychanges, thus providing the operator with Actionable Information inorder to make informed decisions and take appropriate corrective action,if deemed necessary.

Referring to FIG. 17, another exemplary non-limiting fluid method 340includes Performing an Oil Sample Collection (Oil Sample Bottle FillEvent) 340. The fluid device/system 10/120 is able to use this processto precisely and repeatably fill an Oil Sample Bottle 34 for subsequentLaboratory Analysis. Performing a Oil Sample Collection 340 includes thefollowing method steps:

Method step 342: performing a request for an Oil Sample Collect Event.

Method step 344: The fluid device/system 10/120 utilizes on-board insitu sensors 70 to measure the Pressure, Temperature and Viscosity ofthe fluid.

Method step 346: Fluid device/system 10/120 sensor inputs include: 1)Fluid Pressure; 2) Fluid Temperature; and 3) Viscosity of the fluid.

Method step 348: The fluid device/system 10/120 applies the mathematicalfunction for calculation of Solenoid 19 Valve On-Time, where the inputsare defined in method step 346. This function is specifically derived inthe laboratory for a given SAE Grade and/or formulation of hydrocarbonbased lubricant.

Method step 350: The fluid device/system 10/120 performs a system checkto ensure that the Oil Sample bottle 34 is empty.

Method step 352: If the Oil Sample Bottle 34 is not empty, do not turnon the Solenoid 19 Oil Sampling Valve.

Method step 354: Instead, blink applicable fluid device/system 10/120status light(s) 49 and/or 69, send the sampling event information to theRemote Data Server 123 (FIG. 14B) where the appropriate alerts andnotifications are generated. In the case of a ROUTINE sampling event (asopposed to EXCEPTION or MANUAL), wait to perform the oil samplecollection until the sample bottle 34 has been retrieved and an emptysample bottle 34 is put in its place.

Method step 356: The solenoid 19 Oil Sampling Valve is turned on(Opened) for the Solenoid 19 Valve On-Time calculated in method step348. This allows oil to flow to be diverted from the recirculating oilflow path into the Oil Sample Bottle 34, and filling the bottle 34 withthe precise fluid volume per the bottle configuration programmed intothe fluid device/system 10/120 microprocessor firmware.

Method step 358: Once the Solenoid 19 Valve On-Time value has elapsed,the Solenoid 19 Oil Sampling Valve is turned off (Closed) to stop thediverted flow of oil into the Oil Sample Bottle 34.

Method step 360: Blink applicable Solenoid 19 status light(s) 49 and/or69, send the sampling event information to the remote data server 123where the appropriate alerts and notifications are generated and sent(i.e. SMS text message, email, auto-attendant phone call(s), etc.).

Referring to FIG. 18, another exemplary non-limiting fluid method 380includes Temperature Correcting Oil Viscosity Measurements 380. Enablingthe fluid device/system 10/120 to eliminate the effects of temperaturechanges and determine the real departure of an oil's viscosity from theoil's baseline (virgin) viscosity. Performing a Temperature CorrectingOil Viscosity Measurements 380 includes the following method steps:

Method step 382: The fluid device/system 10/120 utilizes the in situfluid property sensor 70 to measure the Temperature and Viscosity of thefluid every 30-seconds.

Method step 384: Fluid device/system 10/120 inputs include: 1) FluidTemperature; and 2) Viscosity of the fluid.

Method step 386: The fluid device/system 10/120 applies the mathematicalfunction for temperature correction of viscosity, where the inputs aredefined in method step 384. This function is specifically derived in thelaboratory for a given manufacturer, SAE grade, and/or formulation ofhydrocarbon based lubricant. Bv=Baseline Viscosity; T=Oil Temperature indegrees Celsius; Bv=(1.5763649+(17018.976/(T×T)){circumflex over( )}2)). Please refer to the above the section entitled: ProprietaryAlgorithm for Real-Time Temperature Correction of Engine Oil Viscosityfor additional support and disclosure.

Method step 388: The fluid device/system 10/120 is able to produce thetemperature corrected viscosity for the oil in terms of “% OF NEW,”thereby allowing for the identification of harmful oil property changes,thus providing the operator with Actionable Information in order to makeinformed decisions and take appropriate corrective action, if deemednecessary.

Referring to FIG. 19, another exemplary non-limiting fluid method 400includes Triggering an Oil Sample Collect 400. The Oil Sample Events canbe triggered in one of three ways, these include: 1) MANUALSAMPLE—manually performed by a mechanic/operator (human), 2) ROUTINESAMPLE—automatically triggered by the fluid device/system 10/120firmware (machine time schedule-based), 3)SAMPLE-BY-EXCEPTION—automatically triggered by the fluid device/system10/120 firmware (Dangerous Condition exception-based). PerformingTriggering an Oil Sample Collect 400 includes the following methodsteps:

Method step 402: The fluid device/system 10/120 counts the machine'soperating time in hours and is able to trigger a ROUTINE oil samplecollection event based on a pre-set (user configurable) interval ofmachine operating hours. This ensures that Oil Samples are collectedconsistently and regularly based on the machine's operation. Every timethe configurable machine hour interval elapses, the fluid device/system10/120 performs an Oil Sample Collect Event and the interval is re-set,starting the countdown over again.

Method step 404: If the fluid device/system 10/120 RESET/SAMPLE button91 is pressed, a MANUAL (human triggered) Oil Sample Collection Eventcan be performed. This enables the user of the fluid device/system10/120 to collect a sample of oil upon demand, or at will.

Method step 406: Any of the three (3) fluid device/system 10/120Sampling Trigger methods (Manual vs. Routine vs. Exception-Based) causesthe Sample Collection process to be activated, this method/process isdescribed in fluid method 340 shown in FIG. 17.

Method step 408: If the Dangerous Condition Method/Process (described inFIG. 15A, 15B as fluid method 200) identifies the presence of aDANGEROUS CONDITION, the Oil Sample Collection process is triggeredautomatically (e.g. Exception-Based method), generating aSample-by-Exception oil sample.

Method step 410: If none of the conditions required to trigger a OilSample Collection process are present, the fluid device/system 10/120will continue its normal operations by default.

Referring to FIG. 20, another exemplary non-limiting fluid method 430includes Auto-Calibration of fluid device/system 10/120 SensorMeasurements 430. Auto-Calibration of Sensor Measurements; The uniquecombination of Real-Time Sensor Data and High-Quality LaboratoryAnalysis allows the fluid device/system 10/120 sensors to beautomatically calibrated if or when the need arises. PerformingAuto-Calibration of fluid device/system 10/120 Sensor Measurements 430includes the following method steps:

Method step 432: The fluid property sensor 70 installed within the fluiddevice/system 10/120 measures several parameters of the fluid flow andstores the measurement values to data storage device (i.e. RAM, ROM,Flash memory) located on the PCBA 111. The data is also transmitted tothe remote Data Server 123 (FIG. 14B) via the internet.

Method step 434: Fluid device/system 10/120 sensor inputs include: 1)Density of the Fluid, 2) Fluid Temperature, 3) Dynamic Viscosity of thefluid, 4) Dielectric Constant of the fluid, 5) Water Content of thefluid.

Method step 436: The fluid device/system 10/120 performs an Oil Samplingevent and makes a sensor measurement at the same time the sensor data issent up to the remote Data Server 123. The Oil that is collected in theOil Sample Bottle 34 is representative of the previously mentionedsensor measurements. Theoretically, the laboratory analysis results andthe fluid device/system 10/120 sensor data values should agree veryclosely.

Method step 438: The Oil Sample bottle 34 is shipped to the oil analysislaboratory where the oil in the bottle is analyzed and the oil analysisdata is sent to the remote Data Server 123.

Method step 440: On the remote Application Server 124 (FIG. 14B), thelab analysis data (method step 438) and the concurrent sensor data(method step 436) are compared against each other.

Method step 442: If the lab analysis data and the fluid device/system10/120 sensor data agree closely with each other, it can be said thatthe fluid device/system 10/120 sensors are calibrated correctly andthere is no need for calibration.

Method step 444: In the case that there is no need for calibration, theprocess is repeated at the time of the next ROUTINE oil samplecollection event.

Method step 446: If the lab analysis data and the fluid device/system10/120 sensor data do NOT agree closely with each other, it can be saidthat the fluid device/system 10/120 sensors are not calibrated correctlyand there is a need to calibrate the fluid device/system 10/120 sensors.The remote Application Server 124 calculates the appropriate calibrationfactor(s) for each affected fluid device/system 10/120 sensor based onthe discrepancy between the laboratory analysis results and theconcurrent sensor data.

Method step 448: The calibration factor(s) calculated on the remoteApplication Server 124 are automatically sent from the remote OutputServer 125 (FIG. 14B) to the fluid device 10 via its wireless data linkin order to appropriately calibrate the fluid device/system 10/120sensors.

Method step 450: Now that the fluid device/system 10/120 has beenauto-calibrated correctly, the Auto-Calibration process is repeated atthe time of the next ROUTINE oil sample collection event.

Referring to FIG. 21, another exemplary non-limiting fluid method 480includes a method/Process for the Application of Dual Timestamps to allrecorded fluid device/system 10/120 Functions 480. This enables sensordata, alerts, alarms, and events to be time-stamped according to twodistinct and important measurements of time: 1) Calendar time, orModified Julian Date (MJD), tracks the actual date/time of an event orsensor measurement; 2) Machine time (MT) tracks the time of an event orsensor measurement with respect to the machine's life history. The fluiddevice/system 10/120 is able to track MT and only increment the MTcounter if the machine is operating. This enables the possibility ofviewing fluid device/system 10/120 events, sensor data, or Laboratorydata with respect to the machine's operating history. Performing amethod/Process for the Application of Dual Timestamps to all recordedfluid device/system 10/120 Functions 480 includes the following methodsteps:

Method step 482: The fluid device/system 10/120 constantly updates thetime values stored in its microprocessor with a clock device(real-time-clock) that is mounted on the motherboard, for example, mainprinted circuit board 111.

Method step 484: The fluid device/system 10/120 has an on-boardreal-time-clock (clock device) that precisely keeps track of the MJDtimestamp (e.g. 2015-08-25 2:45:26 PM). The real-time-clock isautomatically synchronized with a world time server on a regularinterval. This synchronization is performed at period intervals(configurable and programmed in the microprocessor firmware) via a datalink between the fluid device/system 10/120 and the internet. Due to thefluid device/system 10/120 operating in a hot environment as it isdirectly mounted to an internal combustion engine or a compressor, thereal-time-clock synchronization interval is set to an hourly schedule.

Method step 486: The fluid device/system 10/120 utilizes sensor input todetermine if the machine is in operation or not.

Method step 488: Inputs to method step 486 are redundant accelerometersand oil pressure, if oil pressure is not below a threshold, and BOTHaccelerometers register vibration, the machine is in operation (ON). Ifthere is no vibration registered (state 1) AND the oil pressure is belowa threshold (state 2), the machine is NOT in operation (OFF).

Method step 490: If the machine is registered to be in operation (ON),the fluid device/system 10/120 increments the Machine Time counter.

Method step 492: If the machine is registered to NOT be in operation(OFF), the fluid device/system 10/120 does not increment the MachineTime counter.

Method step 494: Any and all new fluid device/system 10/120 events/datapoints are generated as a result of normal fluid device/system 10/120operations.

Method step 496: At the instant of the new event/data point, the fluiddevice/system 10/120 reads the MJD date/time and the MT counter valueand applies both time values to the event or data point in such a waythat they correspond.

Method step 498: The new event/data point, now linked to BOTH the MJDand MT timestamps, is sent to the remote Data Server 123 for long termstorage, analysis on the remote Application Server 124, and output viathe remote Output Server 125.

Referring to FIG. 22, another exemplary non-limiting fluid method 500includes an Oil Sample Collection method/Process 500. Performing an OilSample Collection method/Process 500 includes the following methodsteps:

Method step 502: Oil sample collection event-solenoid 19 actuated valveopens for a calculated time allowing precise volume of oil to fill thesample collection bottle 34. Sample Collection Event is either manuallyperformed by a mechanic/operator (human), or automatically triggered bythe fluid device/system 10/120 firmware (machine-time (MT)schedule-based (fluid method 480; FIG. 21), or Dangerous Conditionexception-based (fluid method 200; FIGS. 15A and 15B)).

Method step 504: Immediately upon an oil sample event, the fluiddevice/system 10/120 transmits a timestamp (machine time (MT), andcalendar time (MJD)) of the oil sample collection event (and all otherpertinent machine information) to the remote Data Server 123.

Method step 506: Once the fluid device/system 10/120 sends oil samplecollection event to the remote Data Server 123, the remote Data Server123 automatically sends out an email/SMS (short message service) text toclient informing of an oil sample collection has just occurred.

Method step 508: The operator/mechanic (human) who is dispatched to theequipment-mounted fluid device/system 10/120 retrieves the FILLED oilsample bottle 34. Prior to removing the bottle from the fluiddevice/system 10/120, the person uses a smartphone/tablet equipped withscanning application and manually scans two (2) labels: 1) the bar codelabel that is on the oil sample bottle, and 2) the QR code that isaffixed to the fluid device/system 10/120 housing 18 (located on innerdoor 24 surface of enclosure).

Method step 510: Various forms of client-facing Actionable Informationcommunications may include: SMS text messages, email messages, real-timeweb-based dashboard, auto-attendant phone calls, etc.

Method step 512: Input-Sample of bar code (affixed to oil sample bottle34) and QR code (affixed to fluid device 10).

Method step 514: Output-Trackable oil sample I.D. number. Oil samplechain-of-custody: machine-customer-lab-database-dash board.

Method step 516: Once the scanned bar/QR code data has been collected,the smartphone/tablet wirelessly transmits the data to the oil analysislaboratory via the remote Data Server 123.

Method step 518: The scanned bar/QR code information for the specificoil sample and machine is linked to a lab analysis I.D. record in thelab's database.

Method step 520: Shipping information is gathered for shipment of oilsample bottle 34 to oil analysis lab; shipping charges are applied andpostage is charged to client account.

Method step 522: After the client has retrieved the oil sample bottle34, the sample is packaged by the client and shipped to the oil analysislab for a detailed oil analysis per ASTM-based protocol.

Method step 524: Oil lab analysis results are automatically uploadedfrom the lab database to the remote Data Server 123 via a developed API.API=Application Programming Interface. (method step 548 of FIG. 23).

Method step 526: Alert notifications are sent to client (i.e., SMS text,email, auto-attendant phone call(s)) informing the client of the fluiddevice/system 10/120-monitored equipment system status from which theclient can choose to take further action (or not).

Method step 528: Shipping label file is generated for shipment of oilsample bottle 34 to oil analysis lab; shipping charges are applied andpostage is charged to client account.

Method Step 530: Various forms of client-facing Actionable Informationcommunications may include: SMS text messages, email messages, real-timeweb-based dashboard, auto-attendant phone calls, etc.

Referring to FIG. 23, a diagram to further illustrate fluid method 500of FIG. 22 for an Oil Sample Collection method/Process. This diagramincludes the following reference numerals:

532: a fluid device/system 10/120 had been provided on amachine/equipment (method step 502 of FIG. 22).

534: Data transmission is performed from fluid device/system 10/120 toremote Data Server 123 (method step 504 of FIG. 22).

536: Oil Sample Bottle 34 is filled with oil ready to be analyzed byLaboratory.

538: Bar code containing unique serial number, affixed to oil samplebottle 34 (method steps 512, 514 of FIG. 22).

540: QR code containing unique machine I.D. information (method steps512, 514 of FIG. 22).

542: Operator retrieves FILLED oil sample bottle from fluiddevice/system 10/120 (method step 508 of FIG. 22).

544: Person (operator, mechanic) who collects physical oil samplebottles 34 and ships to Oil Analysis Laboratory.

546: Remote Data Server 123.

548: Oil analysis test results is data wirelessly transmitted to remoteData Server (method step 524 of FIG. 22).

550: Oil Analysis Laboratory where physical oil sample bottles areshipped and analyzed.

552: Actionable Information (method step 524 of FIG. 22).

554: Wireless data link between remote Data Server 123 andsmartphone/tablet application (method step 506 of FIG. 22).

556: Bar/QR code data scanned by the smartphone/tablet Scanning App andwirelessly transmitted to Data Server 123 (method steps 516, 518 of FIG.22).

558: Shipping label file generated by remote Application Server 124 andwirelessly transmitted to customer for local printing and affixing toshipment of physical oil sample bottle 34 (method step 536 of FIG. 22)to Oil Analysis Laboratory (method steps 550, 520 of FIG. 22).

560: Physical Oil Sample Bottle 34 shipped to Oil Analysis Laboratoryutilizing generated Shipping Label (method step 522 of FIG. 22).

562: Custom shipping label for physical oil sample bottle 34 (methodstep 536 of FIG. 22).

564: Smartphone/Tablet Application used for scanning bar/QR codes andwirelessly transmitting to Oil Analysis Laboratory.

566: Physical oil sample bottle 34 with bar code label affixed (methodstep 514 of FIG. 22).

570: Bottle I.D. and timestamp data wirelessly transmitted to OilAnalysis Laboratory (method step 522 of FIG. 22).

In compliance with the statute, the various embodiments have beendescribed in language more or less specific as to structural andmethodical features. It is to be understood, however, that the variousembodiments are not limited to the specific features shown anddescribed, since the means herein disclosed comprise disclosures ofputting the various embodiments into effect. The various embodimentsare, therefore, claimed in any of its forms or modifications within theproper scope of the appended claims appropriately interpreted inaccordance with the doctrine of equivalents.

1-16. (canceled)
 17. A fluid monitoring and management devicecomprising: a housing comprising a fluid passageway; a fluid propertysensor comprising a sensing element in the fluid passageway; a valve inthe fluid passageway; and a removable bottle mount aligned with thevalve to be selectively in fluid communication with the fluidpassageway.
 18. The device of claim 17 wherein the valve comprises aneedle extending into the removable bottle mount.
 19. The device ofclaim 17 wherein the removable bottle mount comprises a lower bodyportion of the valve structure.
 20. The device of claim 17 wherein theremovable bottle mount comprises a sealing surface of the valve relativeto the fluid passageway.
 21. The device of claim 17 wherein theremovable bottle mount comprises: a vent; and an air filtrationmechanism for the vent.
 22. The device of claim 17 further comprising asample bottle threaded into the removable bottle mount, the removablebottle mount comprising mating threads undersized relative to matingthreads of the sample bottle. 23-26. (canceled)